APPLICATIONS OF IOT IN

MAINTENANCE
MANAGEMENT
BY:
ANUSHKA KHANDELWAL
BASIL BASHEER
SIMRAN ARORA
 What is Maintenance Management?

Maintenance management is all about maintaining the resources

of the company so that production proceeds effectively and that
no money is wasted on inefficiency. There are many software
programs that assist with this process, and there are a few
objectives that a maintenance manager should seek to
accomplish. These objectives are to control costs, to schedule
work properly and efficiently, and to ensure that the company
complies with all regulations.
 What is Internet of Things?

The Internet of Things is the concept of connecting any device

(so long as it has an on/off switch) to the Internet and to other
connected devices. The IoT is a giant network of connected
things and people – all of which collect and share data about the
way they are used and about the environment around them.
 IOT IN MAINTENANCE MANAGEMENT :
IOT/CPS technologies can enable
the design and development of
advanced monitoring strategies
and thus maintenance policies by
adding additional monitoring
capabilities to industrial machines
and equipment providing in such
a way the following
functionalities:
● Integration of secondary processes within the main control
● Modernization of low-tech production systems
● IT/OT Integration
● Maintenance engagement
 IOT in Total Productive Maintenance

Preventive Maintenance Strategies

Managers can depend on sensors to track certain KPIs and

gather the best hard data like average technician response
times, average length of downtime or technician efficiency into
their preventive maintenance schedule with the help of the IoT.
Try embedding sensors on devices to track abnormal conditions.
From there, generate alerts when unscheduled downtime is
approaching to implement an easy preventive maintenance
● Identifying bottlenecks in the operations
● Lead time optimization
● Automation
● Energy management
 EXAMPLE
Steel Manufacturer with multiple plants in India:
● Each plant has multiple arc furnaces that use water cooling
panels for temperature control.
● leakages in the panels were causing safety issues as well as
production losses
● resolve this issue, the manufacturer worked with
Happiest Minds (a Microsoft partner) to build an Azure-based
IoT solution that remotely monitors the panels, detects
anomalies, and performs root-cause analysis.
● The implementation of predictive maintenance has
prevented failures and production delays throughout the
plants while helping ensure employee safety.
IOT-Predictive Maintenance
Manufacturers that implement IoT and predictive maintenance
garner a number of benefits, depending upon need and
application. Benefits may include:

● Reduced unscheduled downtime

● Increased quality
● Decreased costs
● Greater efficiency and output
USE OF IOT IN PREDICTIVE MAINTENANCE IN
DIFFERENT INDUSTRIES
WIND - TURBINE

The RCA (Root Cause

Analysis) of the situation gave
an insight on the operational
limit of the turbine system
which led to such under
performance.
PETROCHEMICAL

The IOT-powered predictive maintenance solutions have also made an

indispensable impact on oil refining and petrochemical companies.The
major challenge faced by oil refineries is that the physical inspection of the
equipment located at deep ocean floor is very dangerous and inefficient
process.
 PROACTIVE MAINTENANCE
With new sensor information, IOT can help a manufacturer
improve overall equipment effectiveness (OEE), save money by
minimizing equipment failure and allow the company to perform
planned maintenance.
BREAKDOWN MAINTENANCE
Unplanned failure Maintenance

When it comes to unplanned failure maintenance, the IOT

enabled devices can make it easier and more efficient to
maintain assets in remote locations.

Example: Connecting assets through IoT like wind farms or

pumps would make assets generate work orders based on their
condition. By using EAM and mobile solutions, technicians would
get exact location of the object that needs maintenance,
described problem and list of spare parts needed to fix the
asset. That would extremely reduce time and costs associated
with emergency repairs in Asset Intensive Industries.
Every industry can find value from IoT devices, but the best results
are possible only if IoT seamlessly integrated with your other
systems like ERP(Enterprise Resource Planning) and
EAM(Enterprise Asset Management) . The IoT can also be a game-
changer for OEMs. It will redefine the business model as
equipment vendors supplement their offerings with software and
data analytics services.
 CONNECTED MACHINES
● Maintenance managers use
M2M techniques to collect data on
KPI
s, such as assets most likely to
breakdown or top causes of
unscheduled downtime.
● Coupled with IoT sensors, M2M
data helps maintenance
managers gain insight into how
often an asset is
underperforming.Using this data,
managers can map out when
downtime will occur and tie this
data back to their preventive
Examples of strategies maintenance teams can use to collect
M2M data include:

■ Vibration analysis: Gauges machine vibration to identify

potential failures.
■ Infrared thermography: Detects radiation to measure
and analyze the heat of objects.
■ Ultrasound: Helps to hear issues that we normally cannot
like a gas leak.
■ Tribology: Measures particles in fluids that prove
mechanical wear.
■ Motor circuit analysis: Analyzes motor health through
detection of electrical imbalances.
■ Laser alignment: Assists in the aligning of rotating
machines.
 IMPROVED INVENTORY MANAGEMENT
● Using the IOT, maintenance managers can connect their stockrooms
to track orders, incoming shipments or low stock.
● The maintenance team has the ability to collect data remotely via
sensors that tracks when certain inventory may be low. From there,
they’re able to connect this sort of data collection to a software device
to produce alerts when certain stock may be close to out.
● If you depend on the power of a computerized maintenance
management system (CMMS), connect your stockroom with your tool
to automate reorders, generate inventory reports and track costs to
avoid shortages and improve budget.
Inventory optimization
The better inventory managers know
their stock, the more likely they are to
have the right items in the right place
at the right time. With the real-time
data about the quantity and the
location of the inventory items,
manufacturers can lower the amount
of inventory on hand while meeting
the needs of the customers at the end
Automation of inventory tracking and reporting

● With RFID and IIoT, inventory managers don’t need to spend

time on manual tracking and reporting. Each item is tracked
and the data about it is recorded to a big data warehouse
automatically.
● Constant visibility into the inventory items’ quantity, location
and movements
● An IoT-based inventory management solution gives
manufacturers precise visibility into the flow of raw materials
and components, work-in-progress and finished goods by
providing real-time updates about the status, location, and
movement of the items
 IOT IN OEE CALCULATION
Internet of Things (IoT) is helping the manufacturing agencies to
improve their OEE evaluation with a detailed understanding of
equipment performance through instrumentation and analytics.
IoT solutions help to improve the OEE values in many ways:

● Analyzing historic process and performance data to

optimize maintenance planning, schedules, and resources.
● Get warnings in advance about the degradation of their
machines, with predictive maintenance to avoid downtime.
● Leading to lower maintenance costs, reduced material and
supplies, and greater equipment availability.
● The production line quality will be carefully monitored. It
will help you to monitor process parameters, find out the
calibration, temperature, speed and production time of the
machines.
● It will help in the management of supply chain. Industries
will be able to compare the previous production results
with the new ones. It will help them to decide how they can
work on their future schedule.
If the data can be presented in a meaningful way, then this will
help in taking the right decision at the right time to achieve OEE
closer to 100% level.
Availability
Early warning of equipment failure can help avoid unplanned
downtime which can improve the MTTR (mean time to repair).
Also, IoT-enabled devices or equipment can send alerts and/or
reminders to the service provider on a real-time basis before any
failure occurs. This will ensure 100% uptime of equipment.
Quality:
Continuous monitoring of the production line can help improve
quality drastically. This can be possible by using IoT-enabled
equipment. The equipment itself can send alerts about
preventive maintenance requests.
Performance:
Connected devices transmit huge amounts of data to a central
location by analyzing the current data along with the historical
performance data (usage pattern), as a result of which
maintenance planning can be optimized.
RFID tags

Radio frequency identification system (RFID) is an automatic

technology and aids machines or computers to identify objects,
record metadata or control individual target through radio
waves.RFID is often seen as a prerequisite for the IoT.
An RFID tag has an ID carrying the information about a specific
object.
I

RFID antennas: An RFID antenna catches the waves from the

reader to supply energy for tags’ operation and relays the radio
signal from the tags to the readers.
RFID readers: An RFID reader, which can be either fixed or
handheld, uses radio waves to write to and read from the tags. It
can read from the number of tags over distance.
CONCLUSION

For maintenance implications, the IOT uses sensors and

connected devices across the industry to easily track key
performance indicators (KPIs) and control ma

chines. We’re left with access to accurate, real-time data to

make the smartest maintenance decisions.
Furthermore, the IOT has the power to completely transform the
industry through proactive maintenance strategies. For instance, with
the help of IoT sensors and data gathering, maintenance managers are
able to better predict when a breakdown will occur based on historic
records and past service requests. A more proactive maintenance
strategy means less equipment downtime, fewer emergency work order
requests and better budget planning.
Thank you!