PREDICTIVE MAINTENANCE AND INDUSTRY 4.0

A CASE STUDY OF THE IMPLEMENTATION OF AN ONLINE ASSET MONITORING SYSTEM

Abstract

IN AN INCREASINGLY COMPETITIVE ENVIRONMENT IN THE INDUSTRY, THE FOCUS ON MAINTENANCE BECOMES PARAMOUNT IN LARGE COMPANIES. IN LARGE PRODUCTION CYCLES, THERE IS A NEED TO SEARCH FOR NEW TECHNIQUES BASED ON INDUSTRY 4.0. IN THIS SCENARIO, THE PRESENT WORK PRESENTS THE CONCEPTS USED IN INDUSTRY 4.0 AND THE MAIN TECHNIQUES USED IN PREDICTIVE MAINTENANCE, AS WELL AS A CASE STUDY TO UNDERSTAND THE BENEFITS AND DIFFICULTIES OF IMPLEMENTING AN ONLINE ASSET MONITORING SYSTEM. THE CASE STUDY WAS CARRIED OUT IN A BUSINESS UNIT OF A MULTINATIONAL COMPANY IN THE MINING SECTOR, WHICH OPERATES WITH THE EXTRACTION OF IRON ORE, NICKEL, PLATINUM AMONG OTHER MINERALS, IN WHICH, IN 2017, THE PREDIX SOFTWARE WAS IMPLEMENTED, WHICH , THROUGH REAL-TIME DIAGNOSTICS, WOULD HELP REDUCE MAINTENANCE COSTS, HELPING TO REDUCE UNPLANNED DOWNTIME AND THUS REDUCING EQUIPMENT DOWNTIME. THE DIAGNOSTICS ARE BASED ON PRE-PROGRAMMED MODELS, WHICH TAKE INTO ACCOUNT DIFFERENT VARIABLES DEPENDING ON THE ASSET TO BE MONITORED, SUCH AS TEMPERATURE, PRESSURE, SPEED, ETC. THE PERIOD STUDIED COMPRISED AUGUST 2018 TO JUNE 2020, WITH AN AVOIDED THEORETICAL COST OF US$ 1,123,389.07. COMPARING THIS TO THE SOFTWARE MONTHLY FEE OF US$ 120,000.00, ADDED TO THE RECURRING FALSE ALARMS, IT WAS NOT POSSIBLE TO SEE A SATISFACTORY COST-BENEFIT IN THE USE OF THIS TOOL. THUS, ITS USE WAS DISCONTINUED THROUGH A MANAGERIAL DECISION. IT HAS BEEN SHOWN THAT, DESPITE THE BENEFITS BROUGHT BY THE USE OF THIS INDUSTRY 4.0 TOOL, THERE ARE STILL MANY BARRIERS TO ITS USE, BOTH FINANCIAL AND OPERATIONAL.