All you need to know about Predictive Maintenance!

Predictive Maintenance

Let’s start with an instance of a second-generation businessman named Mayank. Mayank manages two rice mills single-handedly. He’s tired of following the conventional ways of management passed on from his dad. This forces him to stay at the factory and supervise everything in person. Going on like this, he could never focus on the growth of his plant and he was stuck in that same old process. Machines broke down due to lack of efficient monitoring and also receiving manipulated second-hand data from operators. This led to a significant decrease in production quality and efficiency.

Just when he had lost all hope of effective management and scaling, one of his friends introduced him to Innovation Factory. IF’s IoT based boards convert motors, pumps and mounted bearings into smart wirelessly connected devices which provides real-time alerts of key parameters, such as temperature, current, vibration, etc. to mobile and web app and continuously leverage them to get maximum efficiency. Apart from these an AI continuously works in the background which drives preventive maintenance of key equipment. IF can also automate processes for optimizing quality and power efficiency in production post a thorough audit. Once implemented the entrepreneur could see noticeable RoI in 6-9 months.

Mayank is a free bird now, he manages his time like never before and is already working on setting up new verticals since he need not call 50 people to get individual updates or stay grounded at the factory. He now has a go-to predictive maintenance software for his plants where he can see all the key aspects!

This is how Industrial Automation makes your life easier, and Predictive Maintenance is one of the strongest and most important aspects of Industrial Automation. Now, let’s get into letting you know all that you need to know about Predictive Maintenance.

What is predictive maintenance?

Predictive maintenance is a method through which a production system can be evaluated and maintenance requirements of machines in a factory floor can be anticipated. Patterns are obtained by analyzing operational data from the machines, which help the operators predict when maintenance is to be done on any given unit, before its failure. It aggregates all spheres of data including environmental, process and resource data, and uses AI and machine learning for asset-maintenance.

Earlier manufacturers and factory-owners would rely on reactive maintenance. They would act on servicing their machines only they were broken, and not before that. This was a huge cost both in terms of unplanned downtime and the resulting impact that is cast on the other parts of the machine. The quality of the production was also largely affected.

The mechanism of predictive maintenance could be brought to light with a simple example of ‘vibration analysis’. A system/ device/ model that uses a baseline of performance data for any machine, will detect changes like an increase in the vibration in any specific part of that machine. This could be caused due to any technical malfunction, or damage in parts, or the introduction of some foreign element. Now, any sort of deviation from the baseline data helps the operators to predict a need for maintenance before the trivial issue converts into a serious equipment failure.

Benefits of predictive maintenance:

  • Plant-owners can avoid expensive equipment failures and unscheduled downtime. They can adopt a proactive approach to address the problems and solve them before they significantly influence the production process.
  • Improves production-quality through machine learning and identifies maintenance issues beforehand to increase consumer-satisfaction.
  • Maintenance costs are reduced and equipment life is extended by a significantly visible margin.
  • There as an improvement in production efficiency, asset utilization, and production output.
  • Maximizing uptime and equipment life-span causes significant cost-savings.
  • From the perspective of the employees, reduced breakdowns and accident-prevention systems improve safety conditions within the factory and minimize chances of injuries.All the predictive maintenance advantages mentioned above together work to achieve one exclusive goal- Increasing the Bottom line. With lesser maintenance on healthy components and quicker repair of unhealthy components, repairs can be more effectively handled.

    How predictive maintenance saves cost?

Predictive maintenance does involve some upfront cost in adding the appropriate hardware to facilitate the process, but it saves a huge margin of cost in the long run in the following ways:

Controls system-shutdown and saves costs

Inadvertent system shutdown is the worst-case scenario that could ever be faced by any plant-owner. In such a case, production stops immediately and the owner loses money with every passing second. There also stands a potential risk of the system being repaired incorrectly or incompletely, causing a need for future repairs that would further increase the costs.

Predictive maintenance will help plant-owners/ production-managers to know from beforehand when the system runs the risk of failure. They will, hence, be able to schedule a system shutdown for repairs. This will help repair crews be more productive with a pre-determined agenda in hand.  The manager can plan a temporary production strategy around on-going maintenance, minimizing loss.

Accurate detection of equipment-glitch and Preventing a problem from turning into a catastrophe –

The predictive maintenance software notifies the plant-operations team about the exact problem that has occurred with the exact unit. Since the operations team will already know what exactly has gone wrong, they will not have to rely on any guesswork to proceed with the repair procedure.

Now, the operations team will purchase the exact correct parts required for repair, without any wastage of money. This ensures the most efficient fulfillment of the maintenance process. By doing away with the guesswork and investigating the cause of failure, plant-owners will save money by fixing the system fast and at once.



The opportunities to improve a business that predictive maintenance gives us, are too useful to be left unexplored. It is just the beginning of the potential we are about to come across from the significant reduction in the cost of drawing data and calculating predictive outputs. There is a considerable number of Industrial automation companies available now, that are providing predictive maintenance, to make your production processes easier.

For further query and insight on predictive maintenance of your plant/factory, visit

Economical Steps to initiate Industrial Automation.

Industrial Automation

When you are in a position to be responsible for ensuring the full potential operation of a manufacturing plant, you cannot ignore the talk about ‘Industry 4.0’ and ‘Industrial Automation’. Industrial Automation should not be treated as an obligation. It is a productive combination of improved digital capacities, smarter machines, and sensible cross-channel communication.

Since 2018, we have witnessed a huge digital change. Starting from decentralized cloud-systems to self-directing machines, we have seen it all. However, it is not yet that common. Most plants are slowly approaching towards adopting Industrial Automation. All plants are individually trying their best to make their production line as compatible as possible. They know they need to cope up with the developing, advancing technologies. This way they can slowly optimize their production process. Over the next few decades, a huge transition is expected to take place in the industrial world.

Industrial automation using IoT refers to the use of automated control systems like computers or robots, and information technologies for managing different processes and machines in any industry to replace the labor of a human being. It is the second step to be taken post mechanization in the modern scope of industrialization.

Industrial automation ensures:

  • High productivity
  • High Quality
  • High flexibility
  • High Information Accuracy
  • High safety

One of the most remarkable and influential moves, for availing the solutions for this challenge, is without any doubt, industrial automation through industrial IoT applications. It facilitates factors like improvement in the product quality, reliability, and production rate while reducing production cost and design cost by implementing new, advanced, innovative and integrated technologies, products and services.

In short, industrial automation is the use of IoT in the manufacturing industry through set technologies and automatic control devices that result in the automatic operation and control of industrial processes without any major human intervention, attaining better quality performance than manual control. These industrial IoT devices include PLCs, PCs, PACs, etc. and technologies consist of a varied range of industrial communication systems.

So, how do you begin your journey towards optimizing production-lines in the most cost-effective way possible, alongside assuring long-term ROI benefits? We have come up with 5 effective ways. This can help you set your plant up for new Industrial automation technologies:

1. Consolidate a Single Virtual Server :

Finding a cost-effective storage and data processing solution for your plant is a very difficult job. Also, the solution you choose must comply with the rules and eventualities of your industry. To get started with industrial automation applications, you first need to upgrade a server to a virtual option.

If your plant is exclusively running on physical servers, you don’t need to go virtual right away. There is a very convenient side of Industry 4.0. Most of the software integrations available will integrate with your existing hardware. You will have the option to invest in just one virtual server. Similarly, you can layer software integrations on to it. Most importantly, a single server reduces your costs while maintaining a realistic adaption curve. There are several server options. You can easily consult a process automation expert about the suitability of your server.

2. Arrange for basic Industrial Automation security :

Possibilities of cyber threats increase with an increase in communication on virtual servers. There is nearly no way to avoid this. The easiest thing you can do is to apply two-factor authentication (2FA) for employees. A generic password is not secure enough to protect your data. It’s just a matter of getting the accurate settings implemented and maintaining a protocol that requires every employee to follow the 2FA procedure at all times. This could seem like a dreary matter at the beginning. Therefore, once it becomes a habit, this could bring forth a huge difference in the cyber-security and production office of your plant.

3. Your next purchase must be a Smart Machine :

If you are a new business or you have not adopted automation solutions yet, then it is likely for you to not be in a position to have a completely automated line of smart machines generate highly customized production orders while communicating with and rectifying each other. However, if you are planning to buy a new machine, you should find an automated, optimized one. It must also have decentralized communication abilities. This will be a smart investment that will benefit your plant in the future.

Smart machines

Smart machines are mostly virtually independent of any human intervention. These machines can easily fit into the demands of individual production requirements. This ability of smart machines creates a scalable production process. With smart machines, not only can you produce a larger variety of products, but also enjoy a significantly faster production process.

If your existing machines are working fine and your production is doing fine, you may not replace your existing machines right away with smart machines. Instead, it will be best to go for a smart machine for your next upgrade. Get an automation expert to advise you on the suitable machine, technology, and compatibility with existing plant systems.

4. Implement technological upgrades :

You need to choose your automation products very wisely. You want such applications that help your systems to be compatible with future technological integrations. But, this does not mean that you have to replace all your old applications, programming, and platforms all at once. Most Industry 4.0 automation tools are created in a manner such that they can function on top of your existing process. Also, they do not disrupt the processes you have built to date.

5. Optimize a specific significant plant-process :

The concept of divide and rule works well in this context in a very optimistic way. Just like the idea of upgrading one server at a time, the best idea is to be focusing on just one plant process at a time as well. This could involve optimizing your shipping procedure or optimizing any specific production process. You need to keep in mind: while you experiment with the optimization strategies, you are not just looking forward to gaining a huge return on investment. It is your responsibility to help your employees get comfortable with the new automation system. You approach slowly, with considerable transparency. So, make sure that you include every employee in the process to run them successfully.

Industry 4.0 is generating a world where employees and managers can allot prosaic tasks to the smart machines and rely on them to make processes faster and more effective. Hence, no manufacturing plant should hold back and fall behind in this industrial evolution. To be a part of this evolution, have a look at