There is a lot of talk about Industry 4.0 and its impact on today’s market. But we also need to reinforce the extensions of this concept, such as maintenance 4.0. In turn, it improves already known processes in order to guarantee operational efficiency and availability of industrial assets.
Are you curious? So read on to understand a little more about the subject, as well as its effects, applications and advantages.
Let’s go?
What is maintenance 4.0?
Maintenance 4.0 is directly related to the concept of Industry 4.0. Here, the technologies of the Fourth Industrial Revolution are applied to ensure the correct supervision of the industry’s main assets.
In other words, these tools are used to ensure real-time monitoring, predicting machinery failures, for example.
According to an article on the subject, the main objective is to use the 4.0 principles to benefit from more effective control with the help of optimization and connection.
But for this to happen, it is necessary to combine the concepts of preventive and predictive maintenance and rely on intelligent monitoring and systems integration.
In this way, it will be possible to obtain data from industrial machinery and equipment in order to prevent repairs before they become losses.
Remember that preventive maintenance anticipates possible defects in order to prevent them. This practice generally includes activities such as scheduled inspections, cleaning and intervention applications.
This helps to ensure that the equipment functions correctly, extending its useful life and reducing repair costss.
Predictive maintenance, on the other hand, is based on data and analysis in order to develop a diagnosis of the machine. This helps predict when failures will occur, allowing maintenance to be carried out only when necessary.
Here, continuous monitoring is carried out to identify wear patterns and thus increase equipment efficiency and availability.
In conclusion, maintenance 4.0 is the evolution of traditional methods! It relies on 4.0 technologies to meet the challenges and demands of today’s industry.
In other words, the main objective is to optimize maintenance processes, reduce costs and improve operational efficiency. And this is only possible thanks to data-driven industrial maintenance management.
Remember the definition of Industry 4.0
It is worth highlighting the concept of Industry 4.0 to better contextualize maintenance 4.0 and thus understand its impacts. After all, the second is a direct extension of the first.
The so-called “Fourth Industrial Revolution” concerns the integration of advanced digital technologies and automation. industry. The aim is to guarantee improving processes and increasing productivity.
It is precisely the connectivity of equipment that allows processes and people to be optimized. As a result, industrial resources start to work in harmony, generating agility and operational quality.
After all, it is through the collection and easy access of data that it will be possible to generate insights that contribute to improvement strategies and actions. And that’s exactly what Maintenance 4.0 promotes.
Technologies such as
- Internet of Things (IoT);
- Artificial Intelligence;;” temp_id=”801000″>
- Augmented reality;
- Machine learning;
- Robotics;
- Big Data;
- Cloud Computing;
- Cybersecurity;
- Digital and additive manufacturing;
- Simulation systems.
These tools provide greater automation, real-time data exchange, system integration, operational efficiency and even product customization.
Industry 4.0 transforms the way factories operate, making processes more efficient and productive.
After all, with everything connected, it’s possible to get a macro view of the entire textile industry. This, of course, makes it easier for management to make strategic decisions and, consequently, the developing competitive differentials.
Read also:Textile industry in Brazil: an overview
How does this concept relate to industry?
Maintenance 4.0 in the textile industry guarantees numerous advantages that translate into gains in competitiveness. For example:
- Elimination of unplanned production stoppages;
- Reduced costs for emergency repairs, spare parts and production losses;
- Greater availability of equipment;
- Increased security;
- Higher product quality thanks to stability and operational efficiency.
In addition, the aforementioned article highlights the advantage of information mobility. Intelligent maintenance allows for a more proactive approach capable of improving reliability of operations.
For example, with the Internet of Things it is possible to collect and exchange information between machines remotely. Maintenance 4.0 benefits from electronic devices and sensors connected to the internet to monitor equipment.
IoT is even essential for strategic maintenance management. With it, data can be arranged in graphs and indicators that help analyze efficiency and failure.
In a real-time reading, the study helps with the application of adjustments and the availability of equipment.
Cloud Computing facilitates the storage and access of data, computers and other servers. This contributes to the creation of a large network of shared information.
Meanwhile, Big Data collaborates with operational control. The data generated is organized and analyzed in real time. This helps to predict patterns and establish effective decision-making.
Finally, another article also mentions Augmented Reality as a complete tool that collaborates with:
- Access to technical manuals;
- Highlighting components, electrical schematics and Programmable Logic Control (PLC);
- Technical specifications;
- Step-by-step instructions;
- Highlight specific tools and safety measures during intervention/release of equipment.
How to apply maintenance 4.0?
The examples cited above only reinforce the impact of applying technology in Maintenance 4.0 on operational effectiveness.
After all, with the quality and reliability of the data provided, it will be possible to increase equipment availability, maintenance downtimes and the useful life of the equipment.
But in order to apply this concept, it is first necessary to develop a Maintenance Planning and Control (MCP) that encompasses these tools.
In other words, it will be responsible for ensuring the scalability of the implementation of these new technologies.
To do this, according to the first article, you need to follow these steps:
- Structure a clear perspective on how and where digital will generate value for the bottom line, linked to a clear return on investment;
- Prepare a road map and develop a set of technological partners;
- Adopt an agile approach to developing, piloting and improving digital manufacturing solutions;
- Involve the entire team (including the board) to ensure the success of adoption, transformation management and individual indicators;
- Adapting processes to new methods;
- Draw up a talent management plan.
The MCP must therefore be able to integrate strategy, processes, people and the management system. This plan needs to consider the collaboration between these points in order to guarantee an organized change.
In other words, it will have to structure maintenance management to promote correct integration with 4.0 technologies.
After all, there is no point in applying these tools to maintenance processes without strengthening the organizational culture and everyone’s commitment to the changes.
ow to set up a PCM in the textile industry?
As we have seen throughout the text, Maintenance 4.0 refers to a modern and innovative approach to industrial maintenance management. It incorporates 4.0 technologies to optimize maintenance processes and reduce operating costs.
9 maintenance indicators you need to monitor in the textile industry!
But in order to guarantee these benefits, it is necessary to develop an effective PCM capable of integratingthese technologies correctly. With this in mind, we’ve put together a complete checklist that will help you build this plan.
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