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Machine Condition Monitoring

Machine condition monitoring is the process of monitoring parameters such as vibration and temperature in order to identify changes that indicate a reduction in performance or impending fault. It is a necessary component of Predictive Maintenance solutions and allows maintenance to be scheduled prior to failure, or other actions to be taken to prevent damages to the machine and loss of production. Condition monitoring also provides value beyond improving maintenance schedules. For example, improved visibility into machine operations can indicate the root causes of product defects and can support optimization of energy consumption.

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  • INDUSTRIES
  • Equipment & Machinery
  • FUNCTIONS
  • Discrete Manufacturing
    Maintenance
  • CASE STUDIES
  • Emerson: Refinery Wirelessly Monitors Junction Box Pressure
    The refining company needed to continuously monitor the pressure in Z-Purge junction boxes around the refinery. These junction boxes were maintained at a low positive pressure to prevent process gasses from entering the junction boxes. These junction boxes are widely distributed throughout the plant. Previously these junction boxes were manually monitored by operators on periodic rounds in the refinery.
    PTC: Improving Instrument Recovery Time and Reducing Downtime
    While in the midst of developing SYMPHONY®, a fully automated slide staining system for standard Hematoxylin and Eosin (H&E) staining, Ventana realized that they required a remote service solution to ensure that customers received an exceptional level of service. However, with a tight timeline to develop and launch this new product, there was some reluctance to integrate additional software. “There was some internal reluctance toward implementing the remote service technology with our SYMPHONY instrument given the short timeframe,” explains Greg Dameron, Director of Development at Ventana. “In fact, the executive team informed me that if the software would delay the SYMPHONY launch by even one day, then we would not implement it at all.” The company began evaluating commercial remote service offerings, seeking a solution that would provide value to customers without disrupting system stability. “Our products are based on stability, so we needed the remote service technology to be stable as well,” says Dameron. Ventana sought to reduce instrument downtime to fewer than 24 hours by remotely monitoring all field instrumentation on a 24/7 basis. This would enable the abilities to remotely diagnose and repair issues, provide “over-the-shoulder” troubleshooting and training for users, and track inventory to automatically replenish reagents in real time. “We felt strongly that delivering remote service would help us achieve a response time that we could not otherwise meet,” says Dave Flaten, Vice President and General Manager of the Primary Staining business unit at Ventana. “We believed that it would become an integral part of the product line.”
    Werma: TRW calls for action with the help of WERMA
    TRW needed a wireless monitoring system as laying cables and trunking throughout their sprawling and ageing facility would be an unimaginable task.
  • MARKET SIZE
  • The machine condition monitoring market was valued at USD 2.21 billion in 2017 and is expected to reach USD 3.5 billion by 2024, at a CAGR of 6.7% during the forecast period.

    Source: Markets and Markets

    Machine Condition Monitoring Equipment Market to Cross $3.2 Billion by 2023.

    Source: P&S Intelligence

     

  • BUSINESS VIEWPOINT
  • What are the advantages of Machine Condition Monitoring?

    - Increased machine availability and reliability

    - Improved operating efficiency

    - Improved risk management (less downtime)

    - Reduced maintenance costs (better planning)

    - Reduced spare parts inventories

    - Improved safety

    - Improved knowledge of the machine condition (safe short-term overloading of machine possible)

    - Extended operational life of the machine

    - Improved customer relations (less planned/unplanned downtime)

    - Elimination of chronic failures (root cause analysis and redesign)

    - Reduction of post-overhaul failures due to improperly performed maintenance or reassembly

     

  • STAKEHOLDER VIEWPOINT
  • TECHNOLOGY VIEWPOINT
  • DATA VIEWPOINT
  • DEPLOYMENT CHALLENGES
  • What are the disadvantages that must be weighed in the decision to use machine condition monitoring and fault diagnostics?

    - Monitoring equipment costs (usually significant)

    - Operational costs (running the program)

    - Skilled personnel needed

    - Strong management commitment needed

    - A significant run-in time to collect machine histories and trends is usually needed

    - Reduced costs are usually harder to sell to management as benefits when compared with increased profits.

     

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