CompAir has launched a new white paper to guide owners and operators through the benefits of adopting a proactive maintenance model for their compressed air systems, which could help save up to a third of wasted service expenditure
Entitled ‘Proactive maintenance as a basis for new business models’, the guide highlights the competitive advantage that can be gained by using the Industrial Internet of Things (IIoT) alongside real-time monitoring tools, such as the company’s iConn cloud-based platform.
It then goes on to explain how the IIoT can enable manufacturing companies to build new business models with proactive services, by first defining which services will drive the business forward, then which data is required to achieve this and how the data collected must be gathered, analysed and managed. Finally, the guide recommends focusing this analysis on measurable values such as downtime, failure rates, product quality and troubleshooting speed.
The drive for data
In today’s fast-paced production environment, compressed air systems must be able to work continuously to satisfy the high level of demand. However, 100% utilisation of production systems is not feasible in practice and regular maintenance cycles are required to maintain both product quality and machine performance.
The guide recommends how proactive maintenance requirements should be included as an essential part of the planning process when implementing a network of connected devices through the IIoT.
Proactive maintenance, also referred to as predictive maintenance, intervenes at an earlier point in the process and in many cases prevents a fault, which can often be traced back to insufficient maintenance or incorrect use.
At the same time, sensors are becoming cheaper and more powerful. This means operators can equip their system with numerous touchpoints to set up comprehensive real-time analysis. This data can then be analysed, and the service technician can draw valuable conclusions, such as when the next maintenance interval is due thanks to clear indicators including production time and tool wear. This can help to significantly increase functional reliability and productivity and the savings made can pay for the initial investment in a very short time frame.
The benefits of a cloud-based IIoT platform
The white paper provides strategies to implement a cloud-based monitoring tool, such as the CompAir iConn cloud-based platform. Such systems can deliver savings on hardware costs, with automatic software updates, flexible expansion and easier data sharing. In the case of iConn, the system allows deviations from the optimal plant condition to be detected early and countermeasures to be initiated. This means failures and downtime are avoided and maintenance intervals are not time controlled – but instead, are based on individual component wear and actual system requirements.
Sunil Sharawat from CompAir said, “For proactive maintenance to realise its full potential, the right information must be provided at the right time.”
“However, smart, proactive maintenance requires a proper plan of action and correctly defined interfaces. This white paper from CompAir will help operators to learn some key techniques in IIoT implementation, with specific tips for reducing costs and improving efficiency throughout the entire compressed air system’s lifecycle.”
