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Health And Medical

How predictive maintenance is changing the facial skin of food manufacturing

By Eric Whitley

Food manufacturing is among the most regulated industries in the usa and worldwide. The best reason for all of this regulatory oversight is obvious: to avoid the contamination of food.

Sound, world-class maintenance measures must ensure the best standards of food safety. Maintenance will come in both reactive and proactive forms. The focus should be on the latter however, since reacting to a maintenance issue in a food production facility could mean contamination has recently occurred. This short article will provide a short insight into how predictive maintenance is changing the facial skin of food manufacturing.

Predictive maintenance fundamentals

Predictive maintenance is really a proactive method of maintenance management, so when its name suggests, the goal is to help predict when maintenance ought to be performed. This is a data-driven type of maintenance made to analyze the existing condition of equipment and machinery to be able to arrange for needed interventions.

Predictive maintenance achieves this through the use of predictive analytics that estimate potential (future) failure points. The target is to then schedule corrective maintenance before the possibility of these failure points occurring. Maintenance can thus be scheduled beforehand, and when it really is easiest and cost-effective to take action. Other areas of this maintenance include condition monitoring, asset health evaluation, and prognostics.

You can find multiple advantages to predictive maintenance, including:

  • Enabling early fault detection, i.e. halting impending failures
  • Reduced threat of disruptions to production and downtime
  • Improved performance of production-related assets
  • Optimizing the lifespan of machinery and equipment
  • Overall savings in production costs because of greater asset efficiencies

More cost-efficient maintenance costs certainly are a further benefit. It’s been estimated that predictive maintenance can decrease the mean time and energy to repair (MTTR) by 60%.

Predictive maintenance technology

Predictive maintenance is centered around equipment that has to constantly monitor, record, and analyze equipment, referred to as condition monitoring. Smart technology reaches the core of a lot of this predictive technology, like the Industrial Internet of Things (IIoT), artificial intelligence (AI), and machine learning. An IIoT platform could be connected to a bunch of wireless sensors and probes that monitor everything in food processing operations from temperature and conductivity to vibration and pressure levels.

These technologies allow monitoring systems to be interconnected and action data in tandem with one another. So, for instance, an AI-driven sensor in a filter system can collaborate in real-time with other sensors, in order that production-wide data analysis and aggregations can be achieved on a continuing basis.

There are numerous predictive maintenance technologies in food manufacturing today, which a few of the more prevalent ones include:

  • Oil analysis instruments: Oil build-ups or leakages could be detrimental to equipment. In food manufacturing, this instrumentation is primarily useful for oil-using equipment, such as for example hydraulic systems, compressors, conveyor belts, and refrigeration systems.
  • Temperature sensors: This technique measures for hot spots in electronic equipment or people that have electrical circuits, which might indicate overheating or imminent fusing in equipment.
  • Vibration analysis sensors: The technique calculates if you can find significant changes from exactly what is a machines typical vibration. Deviations regarding vibration, such as for example those near valves or motors, enable early detection of potential malfunction.

Industry 4.0 and predictive maintenance in food manufacturing

Food manufacturing plants are striving to become smarter and much more efficient. Industry 4.0 may be the next degree of industrialization, one predicated on cloud computing, automation, connectivity, and huge amounts of digital data. When Industry 4.0 is combined with connected worker, they form the smart factory.

The smart factory is defined by its advanced of digitalization, particularly in the control of machinery and production processes. It accomplishes this through the use of sensors and probes from the local IIoT and driven by AI, ML, and cloud computing in order that real-time data gathering and analysis can be carried out and analyzed by people.

Problem? Little wonder that predictive maintenance is tailor-made for the digitized, smart food manufacturing facility.

If there remain any doubts concerning the viability of a food manufacturing facility implementing predictive maintenance, then think about this: in accordance with a study by the McKinsey Global Institute, it’s estimated that the implementation of predictive maintenance across manufacturing will undoubtedly be reducing factory costs by around 40% and bring about between $240 and $627 billion in savings for the united states economy.

Ultimately, predictive maintenance includes a pivotal role in food safety. It’ll surely be considered a leading manner in which the meals contamination scandals that continue steadily to hit the could be avoided later on.

Concerning the author: For a lot more than 30 years, Eric Whitley is a noteworthy leader in the manufacturing space. As well as the many publications and articles he’s got written on various manufacturing topics, you might know him from his efforts leading the full total Productive Maintenance effort at Autoliv ASP or from his involvement in the Management Certification programs at The Ohio State University, where he served being an adjunct faculty member.After a thorough career as a reliability and business improvement consultant, Eric joined L2L, where he currently serves because the Director of Smart Manufacturing. His role in this position would be to help clients learn and implement L2Ls pragmatic and simple method of corporate digital transformation.

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