Simple Solutions That Work! Issue 11

42 • Establish and integrate the condition mentoring program with your maintenance management process • Implement continuous improvement Top performing companies using RxM via IIoT, like Emerson and GE, have strong machinery reliability with low maintenance cost simultaneously. Foundry managers currently focus on the most attention grabbing issue while process availability suffers. Because most foundry equipment failures occur at random equipment age intervals, a time based preventive maintenance activity can allow a breakdown, resulting in more downtime than a RxM approach. Hard failures of equipment are more expensive to repair due to costs of procuring parts on short lead time, collateral damage to the machine, and the labor cost of over time repair. These are direct costs and do not take into account any indirect cost such as ill-will or personnel problems resulting from the breakdown. Will Goetz’s graph shows that preventive maintenance is ineffective and results in more loss of time than RxM. Industry 4.0 Industry 4.0 is a name for the current trend of automation and data exchange in manufacturing technologies. It includes cyber-physical systems, IIoT, cloud computing and cognitive computing. Industry 4.0 creates what has been called a “smart factory”. It is called Industry 4.0 because it is the fourth industrial revolution. The three prior revolutions of the modern era are: 1. Mechanization, water power, steam power 2. Mass production, assembly line, conveyors, electric power 3. Electronics, computers, IT, multi-axis industrial robots Modern information and communication technologies like cyber-physical system, big data analytics and cloud computing, will help early detection of process defects (scrap) and production failures (downtime), thus enabling their prevention and increasing productivity, quality, and agility benefits in job shops that have significant competitive value. Big data analytics consists of 6Cs in the integrated Industry 4.0 and cyber physical systems environment. The 6C system comprises: 1. Connection (sensor and networks) 2. Cloud (computing and data on demand) 3. Cyber (model & memory) 4. Content/context (meaning and correlation) 5. Community (sharing & collaboration) 6. Customization (personalization and value)