Predictive maintenance now enables companies to take their first steps toward designing the maintenance processes of their plants much more efficiently. This is absolutely vital, since 70 percent of the total operating costs for machinery, plants and other capital goods are generated during the service phase. This means that, alongside reliability, reducing service costs is increasingly becoming a priority. However, it is worthwhile considering predictive maintenance in the broader context of a completely digitized service chain. Only by linking previously separate service processes, from plant sensors, proactive maintenance, innovative service technologies and logistics all the way to improved engineering, for example, is it possible to achieve the ultimate objective – plants that have the very highest levels of availability with costs as low as possible. Instead of isolated solutions, T-Systems has specialized in systematically and reliably linking service processes, digitized from start to finish. Sectors such as the aviation industry have employed this condition-based maintenance approach for years. The aim is now to transfer this method to other industries and supplement them with new analysis opportunities. The advantages of this Next Generation Maintenance solution can be seen in concrete maintenance and servicing savings.
The Next Generation Maintenance solution brings a digital transformation to the service phase. It completely covers the digitized end-to-end service approach and leaves no question unanswered when it comes to advice. Added to this is a comprehensive implementation package embracing design, transformation and operation. Companies can use this to design the service for their plants in such a way that they can be operated in the most reliable, cost-effective and sustainable way possible. It also draws on the established concept of TPM (Total Productive Maintenance), which focuses on the continuous improvement of production – with zero defects and outages as well as no loss of quality.
Next Generation Maintenance
Modular power strip
How can my company benefit from Next Generation Maintenance?
If an industrial robot or a wind turbine starts running irregularly , it doesn’t take long for damage to ensue. If these kinds of high-tech systems are part of a Next Generation Maintenance solution, downtime can be avoided, because their sensors constantly transmit real-time data that is mathematically analyzed in condition-based monitoring. The predictive analytics processes deliver the correct assessments with a high level of accuracy, in both incomplete and complex data structures. Pioneering Industry 4.0 projects have even shown that just small volumes of data – such as only motor performance, without other production data – can uncover significant irregularities with an accuracy of 86 to 100 percent.
Connected by intelligence
As part of a Next Generation Maintenance solution, it is possible for service technicians to be scheduled to remedy the fault very quickly. The solution for this is an intelligent central platform in a secure cloud or as an on-premise version. It can manage the data, information, assets and procedures, process them for the specific uses, make them available to the service technician on the move and document them to provide a historical record. Integrating the individual functional components creates an end-to-end process chain.
Service on the other side of the world thanks to telemaintenance
Telemaintenance makes it possible to support the local maintenance technicians with specialist knowledge even at small or distant sites. To this end, the service personnel on site transmit all the relevant information to the support desk or the service center using a camera-laser system and oral descriptions. The data is compared with the latest plans and picture files. Close interaction then allows the fault to be remedied jointly. The telemaintenance system automatically records and archives the incident. In this way, experts can be responsible simultaneously for plants all over the world and intervene immediately in the event of an emergency. Where appropriate, reports can also be sent out to machinery of the same construction so that similar faults can be prevented in advance.