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The vision and reality of predictive maintenance

As part of smart maintenance, predictive maintenance has become an important topic among experts in relation to Industry 4.0, the Internet of Things (IoT), Big Data and AI systems (artificial intelligence based on machine learning/deep learning algorithms)! 

After all, traditional maintenance approaches such as the regular maintenance specified by the manufacturer rarely reflect the actual condition of the machines and systems. Instead different applications, operating conditions and intensities of use of the machines have a significant impact on their service life - and consequently, maintenance either comes too early or too late. Even if the cost of early maintenance in terms of the life of a machine is still acceptable, the failure of a machine can have serious consequences. These include downtime costs, delay in performance (with possible loss of contracts or orders), loss of market position and loss of customer confidence.1 Accordingly the predictive maintenance approach promises above all to save costs as well as resources, and even to safeguard the company’s image by preventing failures. Systems are needed that are able to anticipate a possible failure due to wear and tear or the like. An ingenious idea ... 
But what does it look like in practice? What is the reality? Here the experts agree that there are demonstrably still NO universal methods or tools that offer the highest level of reliability in predictive maintenance. Conclusion As long as it is not possible to absolutely reliably predict disruptions in the production process due to failures and wear, the other elements that are actively involved in this context need to guarantee the highest reliability. 
This is precisely where preventive maintenance comes into play - since so-called "C products" such as cleaning agents and lubricants have a direct impact on the reliability of production. The uncertainty factor of electronically controlled maintenance must be countered with the optimal maintenance products and the most intelligent technology. In other words, high-performance cleaning and lubrication products are required at a particularly advanced level which, should the worst happen, have sufficient reserve capacity to ensure the full functionality of the production machines even over an extended period of time. 
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1 Tüv Süd, Akademie/Congress, Anlagentechnik und Betriebssicherheit 
2 “Instandhaltung”, Issue 2/2019