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visibility and real-time data prevents manufacturers
from accurately monitoring machine condition and
detecting faults before they cause breakdowns.
Instead of waiting for downtime to occur, these
manufacturers should invest in devices that can
help them to improve the productivity and
maintenance of their existing systems.
Sensors are not a new technology — the military
used them in 70s and the commerce industry
adopted the technology in the 90s. Now,
manufacturers can use this affordable technology to
gather real-time data about a variety of parameters,
such as temperature, pressure and flow. Accurately
monitoring machine condition across the facility
allows manufacturers to detect and anticipate plan maintenance to replace parts and adapt
issues, planning maintenance in advance to avoid settings to reduce the risk of breakdowns
expensive downtime. interrupting production. As manufacturers place
Engineers can fit sensors to existing equipment smart sensors across their facility, they can gather
to immediately improve operations. Businesses more information and see long term benefits of
should also consider adding connectivity increased visibility. Only operating machinery at the
capabilities to existing machines to allow devices to speed required and improving preventative
communicate over the internet and improve remote maintenance will reduce energy consumption and
monitoring capabilities. Improving the ability to costs across the business. Manufacturers should
collect and share data across the entire factory can also see a reduction in maintenance costs and will
help plant managers implement a successful be able to analyse data over time to see where they
preventative maintenance strategy and keep legacy can make further improvements to productivity.
equipment running efficiently. Back in 2011, Industry 4.0 wasn’t just about
investing in new technology and tools to improve
Long term benefits manufacturing efficiency, but about revolutionising
Smart sensors can also help make long term the way an entire business operates and grows. For
improvements to operations. Traditional motors in a almost a decade we’ve seen companies racing to
machine, for example, are either on at 100 percent become part of this revolution and invest in
power or off, irrespective of the speed the advanced technologies to compete with key
application requires. Smart sensors will detect if industry leaders. However, companies do not need
machines are overheating because they are the budget of larger manufacturers, such as
operating faster than required. Manufacturers can Siemens or Bosch, to transform their business. By
then fit equipment, such as variable speed drives, to taking the time to choose the right adaptations for
avoid premature breakdowns. their facility, whether that’s replacing entire systems
Access to real-time data about certain or modifying current infrastructure, every business
parameters can alert manufacturers to any issues can achieve its own version of Industry 4.0.
with a machine, such as overheating. They can then www.euautomation.com/uk

May 2020 • INDUSTRIAL TECHNOLOGY EXTRA! • p6