MAINTENANCE 4.0 – PAPERLESS

-By Mr. Rushikesh Bhagat

Mr. Ruhsikesh Bhagat

Mr. Rushikesh is presently as strategic Manager in M/s. Honeywell Automation International Pvt. Ltd. and has around 10 years of experience in process automation and instrumentation industry.

In a digital age, letter-writing and postcards have become unfashionable. So it’s even more astonishing that a lot of industrial documentation is still circulated on paper generate several tons of paper documentation every year to eliminate paper-based processes in Industrial maintenance. The program aims to convert
all the primary documentation for maintenance measures and integrate it into the digital environment.

Old weathered or broken plastic signs as well as dirty or corroded metal plates can be seen at many brown field sites. The numbers & letters on them are difficult to identify. This is not a big problem for those who know “their” sites. However poor legibility causes problems for new employees & maintenance & service team & the result is lost time & worst efficiency. 

A better basis is needed for efficient maintenance in form of legible & uniform markings. The most obvious solutions is durable signs that are easy to read such as laser-inscribed stainless steel labels, Going one step further RFID identifiers are reachable even after layer of dust over period of years.

The main advantage of going paperless is Predictive and Preventive maintenance.

Consequences of Minimal Preventive maintenance:-

  1. Pump Failures
  2. Melted Hot Zone Components
  3. Broken Belts
  4. Degraded performance

IDENTIFY EQUIPMENTS WITHOUT LOSS OF TIME

Anyone who wants to bring their identifiers up to date, as possibly part of renovation project should keep in mind that “As Built” and “As Design” are seldom same. It is highly advisable to place identifiers on each asset immediately after installation. ID level systems installed at field level makes this easier.

RFID-HF &RFID-UHF transponders that provide unique identifiers can be built into marking or installation material. This investment enhances security & may pave the way to more sophisticated maintained method. In combinations with software which runs with tablets, which are much more best alternative for paper based check lists for components that require scheduling monitoring. They also reduced efforts needed for documentation inspection activity.

 

FIND THE RIGHT WIRELESS TECHNOLOGY

This type of system requires wireless network with always on connectivity between the tablets & the higher levels MES. If the intention is to support maintenance activities using industrial grade office equipment’s, then a WLAN network is always a good choice. Cable based & wireless system can be coexisting.

Another viable option for small networks with up to around 20acces points is cluster management which greatly simplifies the commissioning process. Only one access point need to be configured. The settings are then propagated to the other access points in the network. It only takes a limited amount of efforts.

And last but not the least, early adopters are the beginning to explore the benefits of Augmented Reality(9AR) applications. The tablets identifies a component or Subsystem or a AR marker. It then displays further information in the camera image such as data sheets, maintenance procedure or a video that shows everything that needs to be done. Measurements such as tank levels or temperature reading from sensors can be displayed from remote location.

For Example In case of pumps & compressors on the other hand raw data from one or just a few machines does not provide sufficient information to generate a maintenance plan, According to experts users are benefited most when data is not stored in local notification system. It is much better that data is made available on cloud platform along with data from a thousand other pumps. This make it possible to identify recurring patterns from the Hodge board vibration, output & other measurement data, Artificial Intelligence(AI) systems can generate reliable projections such as when will the faults occur on which pumps? When it is better to swap machine?  

 

BENEFITS OF PAPERLESS MAINTENANCE:-

  • Reduces need for storage space
  • Less chance of lost or missing documents
  • Lower printing and admin costs
  • Better sharing capability
  • Quicker access to important information
  • Less time spent searching for documents.

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