44 n TALKING INDUSTRY January 2025 www.drivesncontrols.com Using smart maintenance to slash operating costs For the latest session in the Talking Industry series of Webinars, consultant editor Andy Pye interviewed two specialists in smart maintenance and explored how their technologies are complementary. He reports on the conversation. Talking Industry The speakers for the November session of Talking Industry – Donal Bourke from Pemac, and Peter Keckes from Red Lion Controls – quickly identified that they were offering complementary approaches. Before the Webinar, they met virtually to discuss how they could emphasise that companies offering devices that collect data from machines, can liaise with others offering CMMSs (computerised maintenance management systems). With a focus on predictive maintenance and automated workflows, the session concentrated on how advanced technology can transform maintenance management from a traditional reactive expense, to a proactive value generator. Pemac provides CMMS software and services to some of the world’s most competitive and regulated industries. Its products interpret incoming data to provide businesses with insights to help them with their decision-making and to manage their assets. Red Lion Controls supplies industrial automation equipment and is especially strong in North America. In 2023, it was acquired by HMS Networks, which wanted to expand its presence in the North American market. Industrial data acquisition systems can capture real-time data from sensors, systems and assets. This data can be analysed and acted upon to create automated workflows through CMMS software. For example, sensor data can provide advanced warning or analysis that a particular asset is due to fail. A CMMS can take this analysis and create automated workflows to plan maintenance, and assign spare parts and resources to maintain the equipment, thus reducing unplanned downtime. Building on the complementary nature of the two presenters’ expertise, the Talking Industry session set out to explore: n the value of introducing smart maintenance to drive cost savings; n how predictive maintenance enhances equipment uptime and minimises disruptions; n ensuring secure data management across production lines to protect critical information; n combining automation with CMMSs to enable predictive capabilities; n implementing automated workflows that streamline maintenance processes; n real-time analysis and response to events for rapid decision-making; and n shifting company cultures towards proactive, efficiency-driven maintenance management. Donal Bourke, who attended the session from the UAE, outlined the concept of smart maintenance. He showed a diagram where the initials of SM-A-R-T were cleverly deployed: n S = strategy and support – the importance of aligning maintenance goals with business objectives, supported by leadership. n M = maturity and measurement – the value of assessing where an organisation is today and using those insights to drive progress. n A = adoption and adaptability – success isn’t just about technology, but teams embracing and adapting to it. n R = reliability and resilience – how proactive maintenance reduces unexpected failures and builds long-term stability. n T = transformation and training – the importance of continuous learning and growth to stay ahead of competition, particularly when it comes to adopting and embracing technology. Smart maintenance isn’t just about the tools, it’s about the culture and mindset shifts that help organisations to achieve measurable cost savings, improve productivity, and make smarter decisions. Pemac’s real-world experience shows that 30%+ cost savings and 15%+ asset lifecycle extensions are possible. According to Bourke, these are conservative estimates, and will depend on the maturity of an organisation. Peter Keckes highlighted the need for secure data acquisition and the role of ITOT collaboration. The two speakers discussed the challenges of adapting new technologies, the vital role of experienced engineers, and the future potential of augmented reality and digital twins as part of smart maintenance programmes. The conversation also touched on cultural differences in technology adoption, with Europe seen as being more cautious, and the US more proactive. Keckes shared his experiences from different industries with different data integration needs. He highlighted the importance of secure data acquisition. Bourke emphasised the security risks and the need for secure data access. Both agreed on the importance of human knowledge in maintenance, mainly due to the role of experienced engineers in understanding and predicting machine failures. You can still watch or listen The video of this Talking Industry panel discussion is available on YouTube (https://www.youtube.com/@talkingindustry) and as a podcast (via https://talkingindustry.podbean.com) The online panel On the panel for this Webinar were: • Donal Bourke, Director of Sales, Pemac • Peter Keckes, Strategic Account Manager for the UK and Ireland, Red Lion Controls • Andy Pye, Webinar Chair and Consultant Editor, DFA Media
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