How to learn about IoT solutions to improve machine uptime

Ways to improve machine uptime

In today’s competitive manufacturing landscape, it is important to learn how to improve machine uptime. Every minute a machine stands idle translates into lost production, impacting your bottom line. The answer lies in a powerful combination: CMMS software for industrial asset performance management with Real-Time Location Systems (RTLS). 

Evaluating the ROI of Industrial IoT: Manual vs. Digital Monitoring

As factories move toward Industry 4.0, the gap between traditional manual logs and IoT-enabled machine monitoringhas become a critical factor in maintaining a competitive edge. While manual tracking often results in “data silos” and delayed response times, digital transformation in manufacturing allows for real-time visibility into shop floor health. By replacing error-prone paper sheets with Industrial IoT (IIoT) sensors, plant managers can achieve a significant ROIthrough reduced unplanned downtime and OEE improvement (Overall Equipment Effectiveness). Use the comparison chart below to understand how transitioning to a predictive maintenance model can eliminate the hidden costs of reactive repairs and legacy inefficiencies.

CMMS Software: The Brains of the Operation

• Proactive Maintenance Scheduling: CMMS software streamlines preventive maintenance tasks, scheduling them based on manufacturer recommendations, operating hours, or RTLS data. This prevents minor issues from snowballing into major breakdowns.
• Inventory Management: Never get caught waiting for spare parts. CMMS tracks critical parts inventory, ensuring they’re readily available to minimize downtime during repairs.
• Detailed Maintenance History: Track every service intervention on each machine using a panic button. Analyze trends to identify recurring problems and implement corrective actions for long-term improvement.
• Improved Communication: CMMS facilitates seamless communication between maintenance teams, operators, and management. Streamline work order assignments, track progress, and ensure everyone’s on the same page.

RTLS: Real-Time Visibility for Informed Decisions

• Precise Machine Location: RTLS devices attached to machines provide real-time location data. Quickly locate specific equipment for maintenance or troubleshooting, optimising technician response times.
• Streamlined Workflow Management: Monitor machine utilisation and identify bottlenecks in your production shop floor flow. Optimise worker assignments, abnormality managers and equipment usage for enhanced efficiency.
• Enhanced Safety Measures: Track the movement of personnel and equipment in real-time, ensuring adherence to safety protocols and preventing accidents.

The Power of CMMS and RTLS for Asset Performance Management

Imagine a scenario where a sensor on a machine detects a slight temperature rise. The RipplesCMMS software automatically triggers a work order, and the RipplesIPS system directs the nearest technician to the exact location of the equipment. This proactive approach prevents a potential breakdown, saving you time, money, and production headaches.

Benefits of a CMMS-RTLS Integration to improve machine uptime optimisation

• Increased Machine Uptime: Preventative maintenance and faster response times to potential issues lead to significant reductions in unplanned downtime.
• Improved Maintenance Efficiency: Optimize technician schedules and resource allocation with real-time machine location data, MTBR and MTBF.
• Reduced Maintenance Costs: Catch problems early and avoid costly repairs due to neglected maintenance.
• Enhanced Data-Driven Decision Making: Gain valuable insights from combined CMMS and RTLS data to optimise your entire production process.