IIoT

JURY ASSIGNMENT

Submitted by:
G.Karthik
M Vishal Balaji
Ritika Upadhyay
Ssaanvi Reddy
INTRODUCTION
The integration of IoT in manufacturing has led to the creation
of smarter and more efficient systems that can optimize
production, reduce costs, and increase profitability.
Two areas where IoT is making a significant impact in
manufacturing are Predictive Maintenance and Quality
Control. These two concepts sound like a mouthful, but in
essence, they’re simply about making sure that your
machinery is functioning optimally, and your products are of
the highest quality.
Predictive maintenance is all about using data to predict when
machinery is likely to fail and taking preventative measures,
while quality control is about making sure that your products
meet the required standards.
BENEFITS OF USING IOT IN
MAINTAINANCE DEPARTMENT
1.Improved operational efficiency:
By integrating devices and systems, manufacturers can gather and analyze real-time data to identify
inefficiencies in their production processes, enabling them to streamline operations and improve efficiency.

2.Reduced downtime:
IoT technology can enable predictive maintenance, allowing manufacturers to identify potential
equipment failures before they occur and take proactive measures to prevent downtime and improve
productivity.

3.Increased quality control:

Real-time monitoring and analysis of production processes can help manufacturers identify
defects and quality issues in real-time, enabling them to take corrective actions quickly and
ensure products meet specific standards.
4. Enhanced safety:
IoT sensors can detect potential safety hazards in real-time, such as equipment malfunctions or
environmental risks, and alert manufacturers to take corrective actions before accidents occur.

5. Cost savings:
IoT technology can help manufacturers reduce costs by optimizing production processes, reducing
downtime, and improving overall efficiency.

6. Enhanced Production
When equipment breaks down unexpectedly, the production capacity of a manufacturing plant reduces
during the downtime.
IoT predictive maintenance resolves such events by forecasting machine failure and proposing solutions in
due time. Consequently, production follows the planned schedule.

7. Evaluation of Repairs
When a machine shuts down and repairs are made, predictive maintenance ensures that the repair was
successful before you fire up the machine again. This prevents another shutdown to make extra repairs
that you might have missed during the first shutdown.
8. Short Lasting Repairs:
In case of breakdown, there’s a likelihood that a repair will be conducted in a shorter time than when the
failure was not anticipated. Constant monitoring of machine conditions provides a basis to understand a
mechanical failure if it is inevitable.
In a survey of 500 plants, repair times before a predictive maintenance program were recorded and
compared to those after one year of adopting the program. Researchers observed a 60% improvement in the
mean time to repair (MTTR) after the program.

9. Increased Return on Investment (ROI) :

When mechanical failures are identified in time, manufacturers tend to spend less on maintenance
and repair. In addition to that, there is improved productivity when line workers and managers are
focusing on core operations.

10. Better Stock Management of Spare Parts:

Predictive maintenance has the power to forecast the cost of repair, including labour,
hardware, and other overheads.

11. Increased Revenue:

When assets are protected from undue breakdowns, production schedules are fulfilled. In
addition to increased productivity, short repair times and higher production quotas improve a
company’s revenue streams from production.
Application of IIoT in Maintenance
Management
Predictive and
prescriptive
maintenance

Real-time
condition Digitial
monitoring twins

Remote
maintenance

Augmented
reality for Just-in-time
maintenance parts
and repair management

Equipment-as
a-service
 Application of IIoT in Maintenance
Management

Predictive Maintenance

IoT helps you to manage your assets through predictive maintenance. Instead of performing
calendar-based inspections and spare parts replacement, predictive maintenance allows you to
monitor equipment and predicting failures.

Data analysis in real time

Machine-to-machine, is a term that can be used to describe technology that enables other
connected devices to exchange information and execute actions without the manual
assistance of humans. The internet of things takes M2M even further by including additional
element: data. Having access to all data from machinery in one network gives manufacturers
the ability to accumulate and analyze the data and transform it to better predictive
maintenance. That leads to increased customer satisfaction and less warranty claims.
Performance Metrics
By using IoT devices, key performance indicators (KPI's) like mean time between failures
(MTBF) or mean time to repair (MTTR) can be calculated automatically by the system and send
back to reporting dashboards. This then excludes the manual human work of capturing
downtime and ensuring accuracy and availability of data.

Automatic repair recommendations

When equipment breaks down, failure data can be gathered from various different sources,
accumulated and analyzed in real time within the cloud. Options for repairs can be done
automatically by the system, even actions to take can be recommended to the technician if
necessary. Failure data can be used to address the repair, including system operating
conditions at the time of breakdown together with previous repair data from the Enterprise
Asset management (EAM).
Inventory Management
Efficient inventory management can have a powerful impact on reducing equipment downtime
and controlling maintenance budget. Connected stock that monitor inventory levels ensures the
organization only has what is needed on their stocks. If the spare part level drops to specific
level you have set up, with Integrated ERP and EAM system, you can notify procurement
department automatically to order more. With predictive maintenance and data analysis,
manufacturers are able to optimize spare parts stocks, freeing up needed capital and
increasing accuracy of spare parts as well as maintenance budgets.

Remote Assets
When it comes to unplanned failure maintenance, the IoT enabled devices can make it easier
and more efficient to maintain assets in remote locations. As it was mentioned before, IoT
reduces unnecessary visits to remote locations where you need to inspect assets through
predictive maintenance. For example connecting assets through IoT like wind farms or pumps
would make assets generate work orders based on their condition. By using EAM and mobile
solutions, technicians would get exact location of the object that needs maintenance,
described problem and list of spare parts needed to fix the asset. That would extremely reduce
time and costs associated with emergency repairs in Asset Intensive Industries.
FUTURE OF IOT IN MANUFACTURING
Here are a few ways that IoT is expected to impact the manufacturing industry in the future:

1. Predictive maintenance will become even more sophisticated:

As machine learning algorithms continue to advance, the ability to predict when a machine is likely to fail will
become even more accurate. This will lead to even greater efficiencies in maintenance, reduced downtime,
and increased productivity.

2. Quality control will be taken to new heights:

With the growing demand for high-quality products, IoT will play an increasingly important role in
ensuring that products meet strict quality standards.

3.The Internet of Things will continue to grow

As more and more devices become connected to the internet, the IoT will continue to grow
and evolve.
This will open up new possibilities for manufacturers, enabling them to optimize their
processes and improve their overall production.
CHALLENGES OF IMPLEMENTING
IOT IN PREDICTIVE MAINTENANCE
The potential to revolutionize predictive maintenance in the manufacturing industry
say there are also a number of IoT security challenges that must be overcome to
ensure successful implementation.

One of the biggest challenges of implementing IoT in predictive maintenance is data

management. In order to make data-driven decisions, manufacturers must collect,
store, and analyze vast amounts of data, which can be both time-consuming and
expensive.
To overcome this challenge, manufacturers must invest in robust data management
systems that can handle large amounts of data, provide real-time insights, and
integrate with other systems and tools.

Another challenge of implementing IoT in predictive maintenance is the integration

of IoT systems with existing infrastructure.
Many manufacturing facilities have legacy systems and machinery that are not
equipped to communicate with modern IoT systems, which can make integration
difficult and time-consuming.
To overcome this challenge, manufacturers must work with technology vendors and
integrators who have the experience and expertise to smoothly integrate IoT
systems with existing infrastructure.
CASE STUDY:
When it comes to IoT in manufacturing, there are plenty of case
studies that demonstrate the benefits of predictive maintenance
and quality control.

1. Predictive Maintenance:

General Electric (GE) is a great example of a company that has

implemented IoT for predictive maintenance. GE placed sensors
on its wind turbines, which continuously collected data on their
performance.
This data was then analyzed in real-time using machine learning
algorithms, which predicted when a wind turbine was likely to fail.
As a result, GE was able to perform maintenance before the wind
turbine actually broke down, reducing downtime and increasing
productivity.
 2. Quality Control

Coca-Cola is another great example of a company that has used IoT for
quality control. Coca-Cola placed sensors on its production line that
monitored the quality of its products in real time.
The sensors collected data on temperature, pressure, and other
parameters, which were then analyzed using machine learning
algorithms.
As a result, Coca-Cola was able to detect anomalies in real-time and
address them before they become bigger problems, reducing the risk of
producing defective products and improving the customer experience.
These are just two examples of the many successful implementations of
IoT in manufacturing for predictive maintenance and quality control.
By using IoT technology, manufacturers can take a proactive approach
to maintenance, ensure that their products meet high-quality standards,
and improve their overall production processes.
CONCLUSION
Predictive maintenance brings a high level of efficiency to how you use assets. It
saves you from unnecessary machine failure by predicting when a breakdown will
occur.

The technology does this by using sensors to gather real-time data about machine’s
condition and creating performance reports that identify potential maintenance
issues.

Predictive maintenance comes with a range of benefits, including reduced costs,

higher profitability, less production downtime, and longevity of machinery.
REFERENCES
https://www.accruent.com/resources/blog-posts/how-iot-impacts-maintenance-management

https://www.dynaway.com/blog/iot-in-maintenance

https://www.cryotos.com/blog/the-role-of-iot-in-modern-maintenance-management

https://ubidots.com/blog/iot-predictive-maintenance/

https://www.peerbits.com/blog/iot-in-manufacturing-predictive-maintenance-and-quality-control.html

https://limblecmms.com/blog/iiot-maintenance/