| | |

How Predictive Maintenance Technology is Improving Machine Monitoring

March 17, 2025

How Predictive Maintenance Technology is Improving Machine Monitoring

Learn how to leverage solution providers to automate real-time data collection, detect issues early, and optimize maintenance activities.

Introduction to Predictive Maintenance

Predictive maintenance is changing the way industries manage their equipment. Unlike traditional maintenance methods, which rely on fixed schedules, predictive maintenance uses real-time monitoring to detect potential issues early. This proactive approach reduces the likelihood of unexpected downtime and ensures that maintenance activities are performed only when necessary, optimizing resource allocation and reducing costs.

Key Advantages of Predictive Maintenance

One of the key advantages of predictive maintenance is the consistency and reliability of its data-driven approach. Real-time data is available for everyone to read and act upon, minimizing the variability that can arise from individual expertise. This ensures that maintenance decisions are based on accurate and up-to-date information, leading to more consistent and reliable operations. This not only frees up skilled labor for more critical tasks but also reduces overall maintenance costs. By automating the monitoring process, factories can achieve more efficient operations, ultimately improving their bottom line.

Overcoming Challenges in Predictive Maintenance

While the benefits of predictive maintenance are clear, implementing this technology in factories with legacy equipment can present several challenges. One of the primary hurdles is the high initial investment required for predictive maintenance devices and their integration into existing networks. Legacy equipment often lacks modern communication ports, making integration more complex. Additionally, there may be a lack of technical expertise to understand and act on the data collected.

The Role of Solution Providers

These challenges can be effectively addressed by partnering with experienced automation solution providers, like Omron. They can guide factories in selecting the most appropriate monitoring devices and ensuring that the initial investment is justified. They help identify the root causes of equipment issues and recommend solutions that are tailored to the specific needs of the factory.

Simplifying data integration is another critical aspect. Solution providers can suggest devices that are easy to configure and integrate into the existing network, and they can use built-in algorithms to filter and process data, making it more accessible and actionable. Furthermore, they can offer comprehensive training programs to bridge skill gaps and ensure that the data is presented in a way that is easy to understand.

Real-World Success Story

A real-world example of the benefits of predictive maintenance is the case of a global baked goods manufacturer. This company faced significant challenges with manual processes, including unstable data tracking, increased downtime, and safety risks. By upgrading to an automated system with EtherNet/IP for data logging, they improved data tracking, synchronized processes, and eradicated errors. This set the stage for implementing predictive maintenance, which significantly improved production efficiency, safety, and product availability.

Source

More Information

Reduce unplanned downtime with 24/7 predictive maintenance

Related Story

Omron’s K6PM Thermal Condition Monitor: Predictive Maintenance Reduces Downtime

Effective and exhaustive temperature monitoring has traditionally been performed by skilled workers who are adept with using special thermal monitoring equipment to identify potential concerns. These inspections, however, are becoming increasingly complicated because of the ever-increasing number of devices in a panel that are needed to adhere to compliance standards. Simultaneously, the quality and quantity of maintenance workers is receding, making it challenging to provide real-time analysis of thermal conditions in a panel and develop an accurate snapshot of the system.

Related Articles


Latest Articles

  • How Omron’s VHV5 is Making High-Performance Barcode Reading Effortless

    July 10, 2025 Omron’s new VHV5 Ultra-High Performance Barcode Reader is designed for barcode reading applications in industries like automotive, food packaging, and logistics. It offers unparalleled ease of use, automated intelligent setup, and superior performance. Ease of Use One of the standout features of the VHV5 is its user-friendly design. The reader simplifies the… Read More…

  • MOXA Next-Generation LAN Firewalls: Enhancing Industrial Security and Reliability

    July 7, 2025 Cyberattacks on critical infrastructure have become an all-too-familiar reality. While no longer shocking headline news, their effects are far-reaching, disrupting essential services that people and organizations rely on daily. From power grids to transportation systems and water treatment facilities, these infrastructures are at the heart of modern life and are highly vulnerable… Read More…


Featured Article

Revolutionizing Material Movement with Autonomous Mobile Robots

Revolutionizing Material Movement with Autonomous Mobile Robots

In today’s fast-paced manufacturing and logistics industries, the need for efficient and flexible material movement solutions has never been greater. Traditional methods like conveyor systems, forklifts, and manual pushcarts have served us well, but they come with limitations.

That’s why Omron is thrilled to announce the launch of their game-changing MD Series of Autonomous Mobile Robots (AMRs). Read more


Products

  • mGuard Secure Cloud Version 3.1 is Released from Phoenix Contact

    July 10, 2025 The mGuard Secure Cloud from Phoenix Contact allows secure remote access to machines and systems worldwide. Version 3.1 is now available with immediate effect. This version of mGuard comes with numerous new features, including China VPN+, which enables reliable and officially approved VPN connections to China. The new version also supports additional router… Read More…

  • SEW-EURODRIVE Now Offers GearOil by SEW-EURODRIVE in Heavy Industry Gear Units

    July 9, 2025 Optimized Lubrication—Engineered by SEW-EURODRIVE, Now Available for Many Large Industrial Drive Applications SEW-EURODRIVE is proud to announce that GearOil by SEW-EURODRIVE is now available as an option with its heavy industry gear units. This synthetic lubricant, formulated and tested by SEW-EURODRIVE engineers specifically for SEW-EURODRIVE gear geometries and thermal loads, is now offered as part… Read More…