Use Cases Machine Condition Monitoring

Machine Condition Monitoring

Machine condition monitoring is the process of monitoring parameters such as vibration and temperature in order to identify changes that indicate a reduction in performance or impending fault. It is a necessary component of predictive maintenance solutions and allows maintenance to be scheduled prior to failure, or other actions to be taken to prevent damages to the machine and loss of production. Condition monitoring also provides value beyond improving maintenance schedules. For example, improved visibility into machine operations can indicate the root causes of product defects and can support optimization of energy consumption.
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Controlling and Monitoring Tobacco Plants in China
Controlling and Monitoring Tobacco Plants in China
Without the aid of computers, calculating production volume in a tobacco plant is troublesome and error-prone. PC-based monitoring systems that automatically collect production data and keep records can greatly improve in-factory logistics management and machinery maintenance. Combined with the use of networking communications, a Manufacture Executive System (MES) can be developed to improve the overall management of the factory. Our customer is a branded tobacco producer in China. When they came to Advantech, their production lines were already automated with the deployment of Programmable Logic Controllers (PLCs). However, they were still dependent on manual labor to count the amount of cigarettes and other materials, and their engineers had to manually check and record the data-logs stored in the PLCs to produce analyses for repair and maintenance purposes. But with Advantech’s PC-based monitoring machines, installed next to manufacturing machines, related data is shown on touch screens and transmitted to the control center, helping to reduce errors and improve management efficiency.
CONDITION MONITORING
CONDITION MONITORING
Parker wanted the ability to apply a common cloud-based remote monitoring platform across many applications. Compressed air can be expensive and inefficient, so Parker’s innovative Transair piping system was chosen as the initial host product. Parker had a unique chance to create a solution that would help facility managers understand their compressed air systems’ key performance so that they could efficiently manage and optimize this critical system.
TOBYHANNA ARMY DEPOT DEPLOYS WIN-911 SOFTWARE WITH TRIDIUM’S NIAGARA PLATFORM
TOBYHANNA ARMY DEPOT DEPLOYS WIN-911 SOFTWARE WITH TRIDIUM’S NIAGARA PLATFORM
The installation of WIN-911’s alarm notification software at the Tobyhanna Army Depot was done as part of an overall energy efficiency project. In the early 2000s, the base worked to decentralize their coal-fired steam heating plant. This project included the construction of 10 boiler rooms housing 21 new boilers, as well as 37 air rotation units installed in various buildings. The entire infrastructure had to be integrated into HMI/SCADA systems and the existing control systems had to be upgraded. Ameresco, a leading independent energy efficiency company, was selected to head the project. Ameresco, in turn, specified WIN-911’s alarm notification system as the software platform used to instantly alert staff of any problems.

The machine condition monitoring market was valued at USD 2.21 billion in 2017 and is expected to reach USD 3.5 billion by 2024, at a CAGR of 6.7% during the forecast period.

Source: Markets and Markets

Machine Condition Monitoring Equipment Market to Cross $3.2 Billion by 2023.

Source: P&S Intelligence

 

What is the business value of this IoT use case and how is it measured?
Your Answer

What are the advantages of Machine Condition Monitoring?

- Increased machine availability and reliability

- Improved operating efficiency

- Improved risk management (less downtime)

- Reduced maintenance costs (better planning)

- Reduced spare parts inventories

- Improved safety

- Improved knowledge of the machine condition (safe short-term overloading of machine possible)

- Extended operational life of the machine

- Improved customer relations (less planned/unplanned downtime)

- Elimination of chronic failures (root cause analysis and redesign)

- Reduction of post-overhaul failures due to improperly performed maintenance or reassembly

 

What business, integration, or regulatory challenges could impact deployment?
Your Answer

What are the disadvantages that must be weighed in the decision to use machine condition monitoring and fault diagnostics?

- Monitoring equipment costs (usually significant)

- Operational costs (running the program)

- Skilled personnel needed

- Strong management commitment needed

- A significant run-in time to collect machine histories and trends is usually needed

- Reduced costs are usually harder to sell to management as benefits when compared with increased profits.

 

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