How to prevent downtime with Hiotron Machine monitoring system
Whether legacy or new, industrial equipment needs formal maintenance to improve its lifespan. Ageing equipment is one of the top roots of unplanned downtime, hence manufacturers are facing high maintenance costs and should take an advantage of a new strategy. Conventional preventive maintenance is taking place at planned intervals and needs skilled workers to achieve time-consuming manual processes. Issues that are rising between inspection dates may remain unobserved and companies may replace equipment early.
While few companies are still manually reporting data, others are acquiring new autonomous technology to enhance production throughput. Though, with many companies failing to reach the required ROI with these technologies, it is time to examine the numbers and interpret what affects the manufacturing throughput. Manufacturers are continuously looking for ways to generate more good parts and one of the biggest hurdles is machine downtime events. Consultants think that 80% of industrial facilities are not able to precisely measure their downtime. A general estimate is that factories face about 5% to 20% of their productivity loss due to downtime.
Predictive maintenance is a dynamic strategy that includes estimating your equipment’s condition with the help of continuous monitoring. The prime aim is to use real-time data to recognize component failures early, minimize unplanned downtimes and avoid expensive repairs.
In this article, we are sharing several ways that hIoTron can allow your team to quickly resolve these concerns to assure machines are running as much as possible.
Utilizing Real-Time Shop Floor Visibility
Near about 40% of top executives from the top 50 global manufacturing companies recognize that the biggest problem is poor visibility into their shop floor. Shop production data i.e. gathered manually is not precise, real-time nor reliable. Data generally reach the top management very late and crucial decisions are made based on such data.
Having machine data visibility in real-time is the solution to knowing certainly what is happening at any time on the shop floor. And this is exactly how the hIOTron’s system can help.
Every single column on the dashboard describes a machine and Color-coding describes the status of each machine whether it is running or idle or under Maintenance. In this way, operators and managers can see an entire performance analysis easily when a machine is behind its production goals or when the machine is facing a downtime event.
Not only its prompt visibility assist operators and managers to recognize and prevent machine downtimes, but they can also get various production reports and trends such as downtime reasons, OEE of machines with availability, performance as well as quality.
Leveraging Downtime Categorization
The out-of-the-box dashboard drives instant actionability and visibility on the shop floor. Now we will proceed with more advanced features for preventing the downtimes.
Utilizing additional data can enhance response times to downtime events by enabling alert notifications and rule-based workflows.
The touch screen tablets placed at each machine can enable not only machine data collection, but the operator can add manual comments to machine data. This contextual information is helpful for not only recognizing a downtime analysis but can also help at a glance, whether the machine is working as per organizational standards.
Additionally, real-time machine health monitoring helps managers to keep machines running without failure or downtime. Â
In this way, the system alerts the right person at the right time when specific actions need to be taken.
Machine Monitoring & OEE:
The Overall Equipment and Effectiveness (OEE) measurement is often used to scale a plant’s effectiveness. There are various common causes of efficiency loss:
- Breakdowns
- Set up Losses
- Minor halts
- Reduced Speed
- Start-up concerns
- Rework to solve Quality concerns
Improve service and machine productivity with hIOTron custom dashboards and plug and play deviceÂ
Ready to get started with a Hiotron machine monitoring system? Request a demo of an Industrial IoT solution that can transform your shop floor data from insights into actions.