Smart maintenance at automatica

Smart Maintenance

Optimizing production without smart maintenance is inconceivable. Smart maintenance contributes significantly to securing and optimizing the availability of machines, systems and processes.

Digitalizing production has a direct effect on maintenance—maintenance and production are growing together. Smart maintenance is an important aspect of the digital transformation toward flexible production processes such as those required for Industry 4.0. As a result, Industry 4.0 also means Maintenance 4.0.

Integrating an exhibition sector for Smart Maintenance into the range of exhibits at automatica is the logical consequence.

The topic of smart maintenance at automatica 2018

The new exhibition sector for Smart Maintenance at automatica demonstrates how digitalizing production is affecting maintenance in all branches of industry.

It allows those responsible for production and maintenance to find innovative solutions to their shared questions and challenges for optimizing production and maintenance processes in the context of digitalization.

  • Predictive maintenance
  • Condition monitoring
  • Data analytics
  • Computerized maintenance management systems (CMMS)
  • Mobile maintenance (mobile devices)
  • Remote services
  • Augmented reality
  • Retrofit (digital readiness)
  • Tribology
  • Maintenance concepts and methods
  • Consulting

Predictive maintenance: Knowing in advance what will break, and when
Predictive maintenance is a projection of the remaining service life of machine components by continually measuring and analyzing operational and condition data. It makes it possible to predict the need for maintenance as well as the best time to perform it on critical assets/components based on current condition data.

Condition monitoring
Measuring and monitoring technology is the key pillar of predictive maintenance. As part of a consistent network that provides timely data about the condition and performance of a plant or machine (condition monitoring), it is the basis for successful condition-oriented maintenance.

Data analytics
Using advanced analytics, i.e. special algorithms, basic data are used to automatically generate new information and to recognize and display cause-effect relationships and malfunction patterns.

Computerized maintenance management systems (CMMS)
The computerized maintenance management system is the foundation for digital transformation in maintenance. CMMS software manages information that is relevant to maintenance and can serve as the basis for optimizing maintenance processes.

Mobile maintenance (mobile devices)
In the factory of the future, mobile maintenance is an important driving force for the efficient use of systems and machines. The key for simplified and improved processes in maintenance and asset management: Employees in production and maintenance use tablets, smartphones and other terminal devices to exchange electronic data and information in real time.

Augmented reality
Augmented reality makes it possible to identify objects in a facility and supplies all existing underlying data directly to the user’s field of vision in real time. Reality is augmented and expanded by virtual data that is already stored in the system. Whether it comes to scheduling data, maintenance information or operating conditions, augmented reality delivers everything to a mobile terminal device—without the need for special hardware or intervention on the part of the user.

Remote services
The primary focus of remote services is on proactive services and multimedia communication. The most important applications support maintenance and process optimization when using machines and equipment.

Retrofitting refers to the modernization or expansion of existing systems and equipment (that are usually older and no longer being manufactured). There are several million machines that still lack Industry 4.0 connectivity in Germany alone—viewed globally, the market for retrofit solutions is worth billions.

Lubricants and lubricant management are essential for efficient system operation, smart tribology solutions help to save energy and reduce material wear.

Facts and figures: Profit from potential growth and savings

The economic potential of smart maintenance in companies is enormous:

  • Reduce maintenance costs: Up to 30%
  • Reduce downtimes: Up to 45%
  • Increase productivity: Up to 25%

The need to transform the industry is very high:

  • 2 out of 3 production plants in Germany are more than 15 years old.
  • 2 out of 3 companies are already having problems scheduling regular maintenance measures.
  • More than 2 out of 3 companies do not have the technical or strategic capability for Industry 4.0.

Which leads to the following conclusions:

  • ROI factor of 10: Investing one euro in smart maintenance saves 10 euros compared to conventional maintenance.
  • Growth market: Industry 4.0 is based on individual, highly available systems, and system support is developing into a core competency in companies.

Source: acatech—German Academy of Science and Engineering, Fraunhofer Institute for Material Flow and Logistics (IML)

Five good reasons to participate

  • Unique intermeshing of the topics of intelligent production and smart production at a single event

  • Highly relevant to automatica’s target group: More than 5,000 visitors at the 2016 fair came from the sectors for maintenance/repair and production planning/control.

  • Gathering for decision-makers: 82 percent of visitors are decision-makers, and 19 percent play a key role in the decision-making process (automatica 2016).

  • Visitors from all important branches of industry: As an automatica exhibitor, you reach all manufacturing branches of industry—and the automotive, electrical/electronics and metal-processing industries in particular

  • Smart maintenance will be highly visible at the fair and in the lecture program.

Participation alternatives for exhibitors

Whether individual stand construction or low cost combination package solutions – automatica has attractive participation alternatives available at fair prices for the Smart Maintenance area.

The participation as an exhibitor at the Smart Maintenance area necessarily requires the application from a main exhibitor participating in automatica 2018.