Introduction to Smart Maintenance & Industry 4.0

Industry 4.0 has introduced technologies that help maintenance managers increase productivity and quality while controlling costs. Industry 4.0 promises new maintenance management approaches, such as prescriptive and self-maintenance, that leverage AI and complex sensory systems for condition-based monitoring, IoT, big data and Augmented Reality (AR).

This course introduces the learner to modern maintenance techniques in the world of Industry 4.0 and culminates in learners carrying out a practical maintenance task on our state of the art PLC controlled Industrial Sorting Plant.

Sensor-controlled maintenance work is simulated through condition monitoring and the PLC reports the need for maintenance via a message on the HMI panel. Learners are guided through the maintenance procedure using an interface for mobile devices, giving the learner access to both traditional technical documents such as assembly drawings, parts lists, assembly/disassembly methods and notes on safety as well as offering them the option to take the virtual route with support from AR, as another way to carry out the process.

Learning outcomes

On completion of this course a learner will:

● Appreciate the reasons for maintenance e.g. longer equipment life, improved product quality, greater cost effectiveness, improved safety, legal requirements
● Understand different types of maintenance e.g. planned, breakdown, scheduled, corrective, condition-based, predictive, prescriptive.
● Understand ways of determining maintenance frequency.
● Gain an appreciation of the costs of poor maintenance and its effects on production.
● Gain an overview of Industry 4.0.
● Learn about condition monitoring techniques and the associated benefits/challenges.
● Understand the operating principles of common industrial sensors, smart sensors and their applications.
● Gain experience in using condition monitoring to inform maintenance decisions.
● Use AR to assist with a common maintenance task.
● Understand the benefits of using AR for maintenance.