A New Era of Maintenance
Maintenance is undeniably vital for continued productivity, reduced downtime, and the satisfaction of customer demands. However, manufacturers have struggled with the downsides of reactive and preventative maintenance. In the first instance, maintenance has only been carried out when machines have broken down or signs of wear and tear have been identified. The second approach has involved the scheduling of maintenance at set intervals or usage milestones.
The reactive approach to maintenance is the least preferred, as it involves repair work only after machine performance has dropped or breakdowns have occurred. This makes for unexpected production stoppages, with potentially costly downtime and breakdowns in the production process. While there are benefits in taking the traditional preventative approach, it also increases the risk of unnecessary downtime and higher maintenance costs. Scheduled maintenance may be carried out despite the machinery being in good condition, with resources being wasted.
With the rise of Industry 5.0 and smart factories, we’re seeing the introduction of a predictive and proactive maintenance strategy. The integration of AI is enabling the improved monitoring of machine performance and health, with potential issues being identified and servicing being carried out when required. Read on as we explore AI as the new cornerstone of predictive maintenance.
The Power of AI in Predictive Maintenance
AI transforms maintenance through the collection and analysis of data via machine sensors. Continuously switched on, these sensors may transfer data specific to everything from the temperature to the level of vibration and pressure. The AI-powered processing of this data allows for the ongoing monitoring of machine health, with potential issues being identified in real-time. Highly accurate predictions can then be made as to the need for maintenance and repairs. The value is clear, with a McKinsey report revealing the potential to reduce maintenance costs by 10-40%, reduce downtime by 50%, and increase equipment lifetime by 20-40%.
As an added benefit, AI-powered maintenance technologies can also make a difference in bridging the manufacturing sector skills gap. This is a clear issue, with a high proportion of maintenance experts nearing retirement and a shortage of younger people pursuing manufacturing careers. 31% of companies have been reported as outsourcing maintenance operations because skilled individuals are hard to find. The integration of AI is a sound long-term alternative, with an increasing number of equipment suppliers offering this option. AI can be a force multiplier for the existing workforce, enhancing decision-making with data-driven insights.
Additional benefits of AI-powered predictive maintenance include:
- Minimising potentially costly unplanned downtime
- Optimising maintenance scheduling and resource use
- Extending the lifespan of factory equipment
- Reducing production and repair costs
- Lessening the risk of dangerous breakdowns and enhancing worker safety
The Ishida Example
Such benefits are being realised through the integration of AI-powered production monitoring systems such as the Ishida Sentinel. Through the seamless combination of advanced analytics and AI, this system unlocks improved efficiency and reduced downtime. Designed specifically for the monitoring of food sector machines, it can be relied on for the collection of key data and performance insights. Automatically detecting anomalies and deviations, it can be integrated for continuous process improvements. Users are also assured of remote support, with Ishida’s technical experts providing guidance for the reduction of unplanned downtime.
Benefits of the Ishida Sentinel also include:
- Integration with weighing machines, X-ray systems, and other equipment in the Ishida range
- Remote access to Ishida’s generative AI data - anytime, anywhere
- Inclusion of advanced system features for data security and privacy
The integration of Ishida’s advanced monitoring system has made a great difference for a producer of sticky confectionery products. Aware that their previous system wasn’t delivering the required levels of transparency, accuracy, or insights, they opted for investment in the Sentinel 5.0. Connecting a variety of multihead weighers and checkweighers across multiple lines, the Sentinel enabled significant improvements in efficiency and throughput. The production monitoring technology is now being used across the daily workflow, with mounted screens showing live data.
The benefits are bound to be more widely realised, with expected developments in AI-powered maintenance. Manufacturers such as Ishida are leading the way in the integration of advanced machine learning algorithms for more precise predictions. We’re also likely to see the increased use of augmented reality for guidance, together with the adoption of autonomous maintenance systems.
Embracing the AI-Powered Revolution
From the reduced need for manual monitoring and intervention to the more reliable detection of machine issues, AI can have a transformative impact on industrial efficiency. The benefits can be realised through the integration of advanced production monitoring systems such as the Ishida Sentinel. And you can explore the possibilities, with Ishida Europe set to be among the exhibitors at the upcoming PPMA Total Show.
Register today for the opportunity to expand your network, discover real-world capabilities, and gain valuable insights into the development of the manufacturing sector.