Introduction:
Industry 4.0 and digital transformation have ushered in a new era of manufacturing, leveraging advanced technologies to optimise operations, increase productivity, and enable predictive maintenance. In this use case, we will explore how PEMAC ASSETS CMMS software, integrated with a Programmable Logic Controller (PLC) through the PEMAC Industrial Internet of Things (IIoT) interface, enables organisations to implement a predictive maintenance management model by automatically generating work orders based on real-time data collected from production sensors and equipment. This integration allows for early identification and response to machine issues before breakdowns occur, leading to improved equipment uptime, reduced maintenance costs, and enhanced overall equipment effectiveness (OEE).
PEMAC ASSETS CMMS can seamlessly integrate with 3rd party PLC systems to enable full predictive maintenance management.
Solution:
A PLC is a widely used programmable logic controller that controls and monitors production equipment in manufacturing facilities. The PEMAC IIoT interface acts as a bridge between the physical plant equipment and the PEMAC ASSETS CMMS software, facilitating the collection and analysis of real-time data for predictive maintenance. In this use case, plant sensors, such as vibration, temperature, and other production equipment are connected to the PLC. The PLC collects and filters the data from the connected plant machinery and updates defined counters in a database table. The PEMAC ASSETS CMMS software polls the database table on a configurable interval, retrieving the data for analysis. Using predefined rules and algorithms, PEMAC ASSETS CMMS software determines whether a work order needs to be generated based on the collected data. If a threshold is crossed or an anomaly is detected, a work order is automatically generated in the system, triggering the necessary maintenance tasks, such as inspections, repairs, or replacements.
Benefits:
Predictive Maintenance:
The integration of PEMAC ASSETS CMMS software with a PLC enables organisations to implement a predictive maintenance management model. By analysing real-time data from production equipment, work orders are automatically generated based on predefined rules and algorithms, allowing for early identification and resolution of machine issues before they result in breakdowns. This leads to improved equipment uptime, reduced maintenance costs, and optimised maintenance schedules.
IMPROVED EQUIPMENT UPTIME
With predictive maintenance enabled by the integration of PEMAC ASSETS CMMS software with a PLC, organisations can proactively address equipment issues before they cause unplanned downtime. This leads to improved equipment uptime, reducing production losses and improving overall equipment effectiveness (OEE).
REDUCED MAINTENANCE COSTS
Predictive maintenance allows organisations to address maintenance needs proactively, avoiding costly breakdowns and emergency repairs. By automatically generating work orders based on real-time data, PEMAC ASSETS CMMS software helps organisations optimise maintenance schedules and reduce unnecessary maintenance tasks, leading to cost savings and improved maintenance resource utilisation.
ENHANCED DATA-DRIVEN DECISION MAKING
The integration of PEMAC ASSETS CMMS software with a PLC provides organisations with access to real-time data from production
STREAMLINED MAINTENANCE WORKFLOWS
The automatic generation of work orders in PEMAC ASSETS CMMS software based on real-time data from a PLC streamlines maintenance workflows by eliminating manual work order creation and reducing delays. This enables maintenance teams to proactively respond to maintenance needs, improving efficiency and reducing downtime.
Summary:
The integration of PEMAC ASSETS CMMS software with a PLC enables organisations to implement a predictive maintenance management model, leveraging Industry 4.0 and digital transformation technologies. With real-time data collected from production equipment and the automatic generation of work orders based on predefined rules and algorithms, organisations can proactively identify and resolve machine issues before they result in breakdowns. This leads to improved equipment uptime, reduced maintenance costs, and optimised maintenance schedules, ultimately enhancing overall operational efficiency. The seamless interface between PEMAC ASSETS CMMS software and a PLC streamlines maintenance workflows and enables data-driven decision-making, empowering organisations to achieve their digital transformation goals and stay ahead in the competitive landscape.
