Maintenance: From corrective to autonomous maintenance 4.0

Machines and production plants are becoming increasingly complex. Therefore, the forms of maintenance are also in a constant state of change.

Selected AR glasses can also be used in Ex zones

While manual and reactive maintenance still dominated in all economic sectors until the 1970s, first preventive and then predictive maintenance concepts became widespread in all industries as technology became more favorable.

With the implementation of Augmented Reality solutions heralds a new change in commercial and industrial maintenance management.

What does maintenance mean: Definition according to DIN standard

Maintenance is currently still defined in Europe in two different standards (DIN EN 13306 and DIN 31051) and describes the totality of all technical and administrative measures that serve to maintain or restore the condition of an object during its life cycle. An asset is an object that represents potential or actual value to the Company. On the one hand, this includes machines and production facilities, but also electrical systems, construction elements, buildings or the infrastructure of a company. Maintenance goals are to ensure the availability of an object, over the longest possible period of time. This goal unites the Maintenance in industry and manufacturing, as well as the Maintenance in logistics and facility management.

Maintenance in the industry

The Maintenance is therefore important wherever objects are used to create value for an organization. However, the industry has the main need here. Maintenance in industry is a key component of economic production, because the cost of this represents a significant proportion of the total cost of production.

Over the course of time, the industry has seen the development of various Maintenanceconcepts have been established. Basically, three types can be distinguished.

  1. Corrective maintenance
  2. Preventive maintenance
  3. Predictive maintenance

Repairing when something breaks: Corrective maintenance

The corrective maintenance (corrective maintenance) is the oldest form of maintenance. maintenance as it has been since the beginning of industrialization. If a system breaks down or a malfunction occurs, it is repaired.

In the case of deferred corrective maintenance a maintenance plan exists, for immediate corrective maintenance will be repaired immediately. Unplanned corrections are usually expensive because they lead to unplanned plant stops, which reduces plant productivity and thus the profitability of the plant. As production lines become more complex, this problem increases because many pieces of equipment work together, meshing like gears. If a plant fails, this often affects the entire production line or large parts of it.

Advantages of corrective Maintenance

  • Hardly any initial costs
  • Low planning effort

Problems of corrective Maintenance

  • Unplanned stops likely
  • Life cycle of the plant decreases
  • Long-term costs may increase enormously

Repairing before something breaks: What is preventive maintenance?

With preventive maintenance (preventive maintenance) the Maintenance carried out before plant faults or failures occur. This is intended to reduce the probability of failure. For a successful Preventive maintenance requires historical data on the machine to determine the approximate downtime. This time is called Mean Time Between Failures .

Because the data quickly becomes complex, preventive maintenance mostly a maintenance management system is used. These help to collect the necessary data, evaluate and visualize .

For some systems, the manufacturers themselves supply corresponding programs that calculate a Mean Time To Failure and inform the operator of the plant about the necessary maintenance inform This form of Maintenance means prospective Maintenance .

The preventive and prospective Maintenance is based solely on statistical data and not on the actual condition of the plant. Unscheduled stops are possible due to these MaintenanceThe risk of damage cannot therefore be completely ruled out.

Advantages of preventive Maintenance

  • More safety through fewer unplanned stops
  • Better planning of costs for Maintenance and repair
  • Longer life cycle compared to corrective Maintenance

Problems of preventive Maintenance

  • Unnecessary Maintenancescycles are likely
  • Even preventive measures do not exclude the possibility of interference
  • High initial costs for acquiring the necessary technology
  • higher personnel expenditure

Knowing when something is going to break: predictive maintenance

Predictive maintenance follows on from the development of condition-based maintenance. Due to the sharp drop in the cost of IIot sensors, a growing market for various solutions, and the improvement of AI in the Smart Factory predictive maintenance has established its own form of maintenance.

Instead of using a set time frame or frequency of use to determine when maintenance is needed, predictive maintenance uses data to interpolate when the machine is likely to break. With this condition-based maintenance, the actual condition of the plant thus becomes the basis for the maintenance plan. To do this, the machines must have sensors that collect the necessary data.

The success of this approach depends on good and inexpensive measurement technology on the one hand, but also on modern machine learning solutions that are able to interpret the data satisfactorily. Here among other things professional Maintenance software software is used.

This type of monitoring allows maintenance to be performed as needed to correct a specific problem and prevent equipment failure. Because maintenance is only required when failure is imminent, predictive maintenance is often more cost-effective than preventive maintenance.

In addition, predictive maintenance provides better predictability, reducing unplanned stops and thus lowering costs. Maintenance tasks are also often less expensive than reactive maintenance because problems are addressed before a complete plant outage occurs.

Predictive maintenance, however, requires a large initial investment to acquire the necessary equipment to record the data. The operation of the technology also requires qualified personnel who are able to handle the equipment and interpret the data. Technicians must understand both the equipment and the monitoring system. This may require staff training or the hiring of new staff.

Advantages of predictive maintenance

  • Reduced complexity due to automation
  • higher plant availability
  • Better plannability and thus higher economic efficiency of the plant

Predictive maintenance problems

  • Higher investment costs, especially at the beginning
  • Higher demand for better trained personnel

Higher plant availability through mobile maintenance

With the advancement of digitalization in industry, mobile mobile maintenancesolutions are gaining in importance. Using a smartphone, tablet or notebook, technicians can access all data in the ERP and the CRM at any time and thus obtain a precise overview of the plant status. This saves the technician time, allows him to intervene more quickly, and the Plant availability increases.

In our store you will find the best smartphones, tablets and notebooks for the industry.

The mobile maintenance today complements preventive and predictive predictive maintenance and is becoming an important part of effective maintenance, especially with the proliferation of AR solutions. maintenanceconcept for the industry.

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Professional maintenance with augmented reality

Maintenance 4.0: Becoming a market leader with augmented reality

With AR mobile maintenance becomes a way to perform standard maintenance tasks more cheaply and efficiently.

With ALEGER you get a complete solution to map the ever-increasing complexity of plants and the multitude of different data sources directly at the plant. AR software works with smartphones, tablets or smart glasses. Data from the ERP, the CAx and the document management system are combined in a tool that technicians can use directly on site. All content from the important systems is then projected directly into an image of the real world. The technician can access all information directly at the right place and does not have to assign data himself first.

This means that less time has to be spent overall on maintenance spent because individual employees spend less time collecting data: instead, they work through predefined checklists and document faults in one and the same system. At the same time, costs are reduced because paper consumption and the effort required to manually evaluate documents are eliminated. Direct insight into all relevant data on the device also reduces the error rate.

Please also read our articles on this topic:

Conclusion: Maintenance in the industry

Maintenance concepts in industry play a key role in ensuring high plant plant availability and thus also the economic efficiency of the plant.

Purely corrective maintenanceconcepts no longer do justice to the complexity of modern industrial plants.

With the proliferation of IIot applications and most recently augmented reality solutions, the Maintenancemanagement is changing in many places and more and more companies are trying to implement predictive maintenance in the context of Industry 4.0. predictive maintenanceroutines in the context of Industry 4.0.

But companies that rely on preventive maintenance concepts also benefit, for example, from mobile augmented reality MaintenanceALEGER’s mobile augmented reality maintenance solution: By simplifying standard tasks, technicians work more efficiently and make fewer mistakes at the same time.

Of course, we at ALEGER can support you in the use of augmented reality in maintenance. We accomplish this by offering a comprehensive range of AR software, AR hardware, and AR workshops.

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