Maintenance 4.0 in Processing Industries!

Posted by admin on June 24, 2020  / 
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maintenance 4.0

Maintenance 4.0 is the approach of operations and maintenance (O&M) activities for Industry 4.0 technologies (e.g. industrial research, automation, and robotics).

Maintenance 4.0 may break the barriers of older strategies by enabling businesses to maximize the useful life of their production equipment and avoid unplanned downtime, reduce planned downtime, increase processes and safety, reduce energy, and save on costs.

Maintenance 4.0 can be used with intelligent planning to help immediate production and maintenance objectives while ensuring workplace health and safety. Industrial analytics for sensor data that are integrated in-plant machinery is applied with Maintenance 4.0. Artificial intelligence is used to identify progressive deficiencies and repair work may be scheduled in advance. During this time, tools and components can be ordered and repairs scheduled before scheduled shutdown.

Maintenance 4.0 also includes industrial automation and robotics, and drones to minimize physical inspection and automate repetitive O&M activities. It is not easy to formulate a strategy for Maintenance 4.0. An ambitious strategy focused on overinvesting in unproven technology, or a cautious strategy of only waiting on the sidelines is impractical.

Regarding the 4.0 strategic plan, the specific guiding principles are:

  • A guiding concept for a Maintenance 4.0 approach includes the development of practices of data governance and the identification of the importance of operational data.
  • Maintenance 4.0 is costly, and its future effect is important in terms of sales and profitability.
  • Effective implementation will require the breakdown of organizational barriers and coordination between autonomous groups.
  • Industrial plants should evaluate the best maintenance practices that can be implemented in conjunction with maintenance 4.0.
  • Maintenance 4.0 cannot be successful if the views of plant-level workers are not taken as part of the process of requirements.
  • Maintenance 4.0 will remain in the planning process without allocating money for training and onboard.
  • Industrial plants should take the time to understand and find mutually beneficial ways to match investments and strategies for their major OEM suppliers’ strategic road map.
  • Maintenance 4.0 adoption belongs to those who are capable of improving and recognizing the organization’s dynamics and policies.

Maintenance 4.0 functional solutions

  • In plug-and-play modes, IIoT will help to ensure flexibility and reduce financial harm through employee health, increased liquidity, and a reduction of short-term costs.
  • In the production plant to assist local technicians, machinery experts need not be physically present.
  • Remote expertise in root cause analysis and performance optimization guidance can be carried out from anywhere in the world.
  • Drones and robots are relatively easy to implement for these maintenance tasks and need to be explored in ways to improve the safety and health of the employee.

The Future of Maintenance 4.0

  • Maintenance 4.0 continues to grow and deliver a more precise, quicker diagnosis that enables businesses to respond much more rapidly.
  • In addition, virtual reality will emerge as an enhanced communication form between operators and technicians.
  • Devices like smart glasses allow engineers to digitally display defects and analyze the situation far more in detail.
  • As IoT evolves further, connected devices that use cloud computing are the workhorses for a successful PDM program.


In order to gain insight into asset behavior, Maintenance 4.0 is to use connected devices to move the plant from reactive maintenance to PDM and prevention to improve reliability and results dramatically.

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