So-called maintenance 4.0 is one of the pillars of technological transformation in industry. But what does it mean? This concept refers to the Digital Age we live in, marked by the use of technology, artificial intelligence, and the Internet of Things in different aspects of the manufacturing environment.
Given this scenario, companies that invest in these types of advances and seek to bring them into their operational cycle end up reducing costs, maximizing earnings, and consolidating their market competitiveness.
But what are the characteristics of this new area, its differentials, and benefits? Read on and discover the answer to these and other questions.
What is maintenance 4.0?
Maintenance 4.0 comprises a set of actions that, through the use of digital tools, quantitatively and qualitatively improves the predictability of failures and defects in machinery and across all stages of task planning.
This is because, with artificial intelligence, big data, and algorithm applications, it is possible to improve the quality of maintenance operations, reduce the costs involved in corrections, and provide more resources for the technical development of the team involved.
Due to all these advantages provided by this process, production downtime is avoided and, when it does happen, it is planned to occur at convenient times. This allows for lower losses and better performance, which is ultimately felt across all operational aspects.
What differentiates maintenance 4.0 from traditional maintenance?
While in traditional maintenance teams acted reactively, now, with maintenance 4.0, it is possible to establish an action plan and have accurate forecasting, enabling a predictive approach.
This means that, thanks to the technologies employed, work is optimized to prevent failures from occurring, going far beyond the old model since actions are now based on intelligent forecasts.
Along the same lines, processes become automated and follow a schedule proposed by the software itself, eliminating human error, guesswork, and inaccurate data. The benefits and positive impacts can be seen in the aspects we will show below.
Better predictability
While previously an exhaustive study full of approaches, charts, and observations was required to obtain a failure predictability index, now with maintenance 4.0, the technology itself takes over this task.
The result is a significant improvement in this probability, even helping to prevent bottlenecks from occurring.
Less idle time
Maintenance involves shutting down machines and halting all operations. However, automation and intelligent planning make these activities more agile, faster, and more efficient, reducing idle time and reflecting in increased productivity.
More developed team
Once technicians and professionals involved become familiar with and learn to handle these specific technologies, they become more qualified, developed, and prepared, contributing to an increase in plant performance.
5 benefits of maintenance 4.0!
In addition to the advantages mentioned, the benefits provided by maintenance 4.0 cover an even more extensive list in the industrial environment.
The positive impacts that this advancement brings to production are countless, but the most expressive ones usually appear in the quality standardization of the final product and even in the supply chain.
Discover below 5 other qualitative points provided by this type of maintenance.
1. Proactive solutions
Unlike the traditional model performed after an event occurs, maintenance 4.0 technologies act based on proactive solutions—meaning they do not wait for an event to happen or a problem to take shape before intervening.
Due to the ability to collect and analyze data, the process becomes based on assertive predictions enabled by intelligent forecasts, continuously and consistently.
2. Higher quality
With this tool, virtual reality tests are performed, consistent equipment performance evaluations are carried out, and machines operate at their maximum capacity.
The result of combining these attributes is the establishment of higher quality final products, as there is greater control throughout the production chain.
3. Machine Learning
Machine learning is a form of artificial intelligence that operates through the use of data and algorithms. This means that in maintenance 4.0, software learns from events and historical data.
Thus, it is possible to recognize patterns, predict failures, and suggest more efficient measures, as well as indicate the best times to perform predictive maintenance without impacting or even without the need to stop production.
4. Remote management
Remote management is another convenience provided by technology. This means that managers and supervisors can access files, performance analyses, and other features online.
Cloud technological solutions are responsible for bringing this practicality to management routines, making planning faster and allowing real-time information tracking.
5. Greater production capacity
Finally, one of the greatest benefits of maintenance 4.0 for industries is the reduction of machinery downtime, contributing to a greater productive capacity and maximizing profits.
It is undeniable that factories have undergone relevant transformations in recent years, and with these changes, repair models have also been impacted. Just like in various aspects of life, technological advances manage to positively influence the environment.
Therefore, investing in technological solutions has never been more important for today’s economy, marked by the pursuit of competitiveness and the presence of constant challenges.
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