How Software Can Help Manufacturers Manage Plant Assets

Having the ability to monitor equipment with real-time capability is a practice that is shown to be important in today’s manufacturing environment. This is directly related to the Industrial Internet of Things (IIoT) and how we protect our assets. It’s mainly a financially motivated practice, but monitoring systems can assist with altering production in a way that best suits the business.

The way machines are monitored affects all levels of a standard operation such as the executive and financial side of saving costs while being able to alter productivity on the ground level of employees physically operating and monitoring machinery. In this article, we’re going to take a look at what parts can be monitored and how they will help businesses become equipped with real-time knowledge of current assets.

bottles-assembly-fillingIt's interesting to look at how many industries are adopting new technologies within their machinery to monitor performance, health, and how each facet of each machine affects productivity. We categorize this behavior as asset monitoring and improvements in this concept could save businesses from wasted expenses when it comes to unnecessary energy output. With new software being applied to these machines, the capabilities can span further than just monitoring a machine’s health. Applications of this technology can allow a business to manage obsolescence, plan ahead for repairs and parts orders, or budget for the future for depreciation expenses.

Now let’s look at what improvements and measures are being taken:

Wireless Asset Monitoring Capability

Traditional monitoring systems usually required expensive wiring and infrastructure to enable each device connected while also entire full shutdowns of equipment in order to be inserted into process lines. With advancements in this field, expensive investments and shutdowns are no longer required due to their new-age wireless capability.

Pressure Relief Valve Monitoring

Pressure relief valves are among the most crucial assets when dealing with pressurized machinery protecting equipment and preventing process upsets and equipment failure. These are usually monitored manually or not efficiently due to high costs. Now, wireless solutions replace manual monitoring and send data to software applications that alert any leaks or malfunctions.

manufacturing-plant-floor-blue-squareSteam Traps and Wireless Sensing

Steam lines are primarily used for heating processes or powering equipment. However, a failed steam trap releases steam to the atmosphere, which wastes energy and could lead to diminished quality of product. Adding wireless sensing devices and using software applications can give operators a view into the system and show energy costs of leaking steam traps.

When they go unmonitored these costs can be up to millions of dollars per year, so implementing of this technology can allow businesses to monitor these costs and prevent further leaks.

Heat Exchangers and Monitoring

Heat exchangers transfer heat from heating fluid to process fluid.

With continuous monitoring, much like the other processes listed above, any deficiencies and lost energy costs can be calculated and either fixed or taken into account.

With these processes improved through the use of software applications and wireless monitoring, it businesses will be able to save on costs in several different areas. Aside from saving expenses, saving energy is a large part of the benefits as well, since monitoring assets and unnecessary energy losses could allow for meeting better environment initiatives. Saving energy in every way is crucial for maximizing profits and processes, and machines that require a lot of fuel and power are the largest culprits of wasting energy, which in turn wastes money and profits.

The ability to monitor equipment in real time is an important component for maintaining consistent production and protecting assets. By managing equipment effectively, operations can continue production while saving costs in the short and long term. Asset depreciation is a key expense of businesses and with the ability to monitor the health of equipment closely really frees up businesses to plan for the future.

How does your operation maintain equipment effectively?


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