iqonic-blog
Client name :
Breka Manufacturing Industry
Category :
Energy / Manufacturing
Location :
Allentown, New Mexico
Date :
15-05-2022

Predictive Maintenance for Manufacturing Equipment

Breka Manufacturing specializes in the production of diverse consumer goods. The company recognizes the pivotal role of reliable and high-performance manufacturing equipment in sustaining top-notch production quality while minimizing downtime. The impact of unplanned equipment failures, with the associated production disruptions and repair costs, underscores the need for a proactive approach.
To tackle this challenge head-on, Breka Manufacturing has introduced a state-of-the-art Predictive Maintenance Dashboard. This innovative solution, powered by Power BI and utilizing a Python ML model for accurate predictions, is complemented by an embedded Power Automate workflow. This workflow seamlessly initiates work orders with vendors, effectively managing identified machine parts that require upcoming maintenance. This strategic integration ensures a proactive and streamlined maintenance process, enhancing operational efficiency and minimizing the risk of unexpected disruptions.

Challenge

  • Equipment Reliability: Breka Manufacturing faces the challenge of maintaining the reliability of its manufacturing equipment. Ensuring that machinery consistently performs at optimal levels is crucial for sustaining high-quality production.
  • Downtime Management: The company needs to address the issue of minimizing downtime. Unplanned equipment failures can lead to costly production disruptions, impacting overall efficiency and potentially affecting the timely delivery of goods to consumers.
  • Costly Repairs: The potential for unplanned equipment failures poses a financial challenge. The associated costs of repairs can significantly impact Breka Manufacturing’s budget and profitability, making it essential to find ways to mitigate these expenses.
  • Workflow Efficiency: Streamlining the maintenance process and managing work orders effectively is a key challenge. Breka Manufacturing aims to optimize its operations by implementing a Predictive Maintenance Dashboard, but ensuring the seamless integration of this system with vendor workflows requires careful consideration and management.
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Project Benefits and solutions
The Predictive Maintenance Dashboard monitors the health and performance of each machine in real time. It uses IoT sensors and historical data to predict when a machine is likely to require maintenance. When maintenance is predicted, the dashboard alerts the maintenance team.
The Dashboard also provides real-time insights into machine performance, such as rotational speed and temperature. By tracking this data, Breka Manufacturing can identify underperforming machines and take corrective actions promptly.
The dashboard has a Power app keeps track of the usage of spare parts by monitoring maintenance events. When a machine is predicted to need maintenance, the system also suggests the required spare parts and starts a workflow.

Benefit:

  • Embracing a predictive maintenance model allows Breka Manufacturing to move away from fixed preventive schedules, leading to substantial cost savings by minimizing unnecessary maintenance and reducing downtime.

  • Proactive issue resolution enables Breka Manufacturing to significantly decrease unplanned downtime, ensuring the maintenance of production schedules and timely deliveries. This approach enhances customer satisfaction and strengthens the company’s reputation.

  • Breka Manufacturing achieves optimal spare parts inventory management, reducing costs while guaranteeing the availability of critical parts when needed. This strategic approach ensures operational efficiency and cost-effectiveness.

  • The optimization of machine performance not only increases throughput but also minimizes energy consumption, resulting in significant cost savings and a more environmentally friendly production process. Breka Manufacturing can achieve a balance between efficiency and sustainability, aligning with eco-conscious practices.

solution:

  • The Real-time Monitoring System oversees the well-being and operational efficiency of each machine through the Predictive Maintenance Dashboard. Utilizing IoT sensors and historical data, the dashboard anticipates when maintenance will be necessary, promptly notifying the maintenance team upon prediction.
  • Additionally, the Dashboard offers immediate insights into machine performance metrics, including rotational speed and temperature. This functionality enables Breka Manufacturing to swiftly identify underperforming machines and implement corrective measures.
  • Complementing this, a Power App integrated into the dashboard meticulously tracks spare parts usage by monitoring maintenance events. In the event of a predicted maintenance requirement, the system not only suggests the necessary spare parts but also initiates a seamless workflow to address the identified maintenance needs. This integrated approach ensures a proactive and efficient maintenance process, minimizing downtime and optimizing overall equipment effectiveness.