Machine monitoring - why is it key to more efficient production?

Estimated reading time: 8 minutes

TL;DR:

• Machine monitoring enables faster response to breakdowns and prevents long downtimes.
• It helps to save costs, plan maintenance more efficiently and increase production quality.
• It is a key component of Industry 4.0 solutions and provides the foundation for predictive maintenance.
• It extends the possibilities of integration with robotisation, giving a coherent view of the entire production process.
• An investment in machine monitoring can quickly pay for itself through a marked improvement in efficiency and a reduction in losses.

Table of contents

• Introduction
• What is machine monitoring and why is it becoming more important?
• Key benefits of machine monitoring
• Practical aspects of implementing monitoring in a production facility
• How to choose a machine monitoring model?
• Extension of machine monitoring with predictive maintenance analytics
• Example - monitoring and robotisation as a coherent ecosystem
• Practical implementation tips in the context of systems integration
• Machine monitoring versus efficiency - can the return on investment be quantified?
• The most common challenges in machine monitoring
• Machine monitoring - key recommendations and conclusions
• SUMMARY
• FAQ

Introduction

Machine monitoring in industry is now becoming one of the most important aspects of production optimisation. It allows us to track key parameters of equipment such as machine tools, presses, assembly lines or industrial robots in real time. As a result, we can react more quickly to failures, reduce downtime and rapidly improve the quality of the manufacturing process.

In this article, you will learn what machine monitoring is, what benefits it can bring to your company and how to implement this solution in practice. Specialists from Michale Automatika have been using monitoring in machine and production line construction projects for years, so we will present this topic from the theoretical and practical side. After reading the text, you will understand why machine monitoring is indispensable in modern companies and which tools and strategies you can use.

What is machine monitoring and why is it becoming more important?

Machine monitoring is the process of continuously collecting, analysing and visualising data from equipment operating in an industrial plant. The aim is to identify possible abnormalities, failures or drops in efficiency on the basis of specific operating parameters (e.g. speed, temperature, pressure, bearing condition, energy consumption). This issue has become increasingly important in recent years due to the rapid development of Industry 4.0 solutions, where data has become a key aspect of managing and improving production.

Key benefits of machine monitoring

Machine monitoring offers tangible gains in terms of efficiency and safety at work. Below, we list the key benefits that encourage various companies to implement monitoring systems.

Elimination of downtime and faster response to failures

• With real-time diagnosis unplanned stoppages that generate financial losses are avoided.
• Monitoring parameters allows failures to be predicted in advance. Once the system notes anomalies, repairs can be scheduled at a convenient time and costly line downtime avoided.

Saving on costs and human resources

• Constant inspection of equipment reduces operating costs. Machines repaired preventively tend to be less stressed and last longer.
• The distribution of maintenance tasks promotes better use of staff and precludes the need for immediate intervention in emergency situations.

Improving quality and safety at work

• Analysing machine behaviour and performance results in a higher quality final product. When machine parameters are kept within the optimum range, the risk of defects is reduced.
• Monitoring also helps to ensure safety. If there is an abnormal rise in temperature or pressure, the system will immediately alert the operator.

Increasing the efficiency of the production process

• Information on working time, productivity or downtime can be used to optimise the entire production line.
• By monitoring machines, so-called bottlenecks, or flow constrictions, can be identified. As a result, we improve work organisation and eliminate production bottlenecks.

Practical aspects of implementing monitoring in a production facility

Until a few years ago, machine monitoring was mainly the domain of large industrial concerns. Today, it is also becoming available to medium-sized and smaller companies. However, for the system to work effectively, there are several key elements to consider.

Definition of the purpose and scope of monitoring

• Before you install sensors and set up data collection systems, clearly define which machines and what parameters you want to measure.
• For example, if your biggest concern is the frequent failure of motors, focus on monitoring the temperature, vibration and inrush current of these components.
• For robotic workstations, it will also be useful to track the number of cycles and the load on the drives.

Choosing the right platform

• There are quite a few software and hardware solutions for machine monitoring on the market. The choice depends on the characteristics of your production line and your IT background.
• It is worth betting on a scalable platform that will enable future growth of the system and integration with other tools (e.g. ERP, MES) so that data and reports can be managed in one place.

Integration with existing automation and robotisation

• If your plant has robotic workstations or you intend to implement them (e.g. welding or laying stations), it is worth ensuring that monitoring also covers robot interfaces.
• Michale Automation has been involved in both machine building and the implementation of industrial robots for years, so we advise on the complete integration of control and monitoring systems.

Data analysis and visualisation

• Simply collecting information will do little if it is not properly processed in real time and presented in an accessible format.
• Performance dashboards (dashboards) should clearly illustrate the status of the line (graphs, indicators) and generate warnings in the event of alarming values.

How to choose a machine monitoring model?

Depending on the needs and specifics of the production processes, several main models can be distinguished:

Stationary monitoring

• The sensors remain permanently installed in the equipment. The system continuously records key parameters (current, RPM, vibration, temperature).
• This solution works well in larger plants where multiple machines need to be continuously monitored.

Mobile monitoring (interim diagnostics)

• The operator or technician has an instrument (e.g. a vibration or noise analyser) and periodic measurements are taken at selected points.
• This model is cheaper to start with, but provides less scope for long-term analysis and it is more difficult to respond quickly to sudden failures here.

Cloud-based solutions

• Data is uploaded to the software in a SaaS (Software as a Service) model. This allows the user to access the information from anywhere in the world - all that is needed is a web browser.
• Cloud solutions are easy to scale, while at the same time they may require special security features and high network bandwidth.

Extension of machine monitoring with predictive maintenance analytics

An important step in the development of machine monitoring is the integration with tools that allow predictive maintenance. The idea is to predict the point at which equipment starts to show signs of wear and tear, so as to avoid costly emergency repairs.

• Models based on artificial intelligence and machine learning can process large amounts of sensor data.
• The system automatically suggests a replacement period for parts (e.g. bearings), so that maintenance is planned in advance and does not affect production continuity.

Example - monitoring and robotisation as a coherent ecosystem

In addition to the supervision of machine operation, the integration of industrial robots into the monitoring system gives a new quality to production management. If you have automated and robotic lines, then:

• The robots send data on the current load, the number of cycles performed or the time of uninterrupted operation.
• You can combine machine monitoring with analytics for the entire process, including workstations, inter-process transport and material storage.
• This will help you detect which areas are the least efficient and identify the untapped potential of the line.

If you are considering the robotisation of certain operations - for example those associated with repetitive manufacturing - take a look at the Robotisation of repetitive production. There you will find basic information to help you combine monitoring with automation.

Practical implementation tips in the context of systems integration

Machine monitoring - especially when combined with modern automation components - can sometimes be demanding at the level of technology selection and planning. Here are some practical steps to consider.

Audit of existing infrastructure

• Before starting work on the monitoring system, check the current status of the cables, the industrial network (Ethernet, Profinet, EtherCAT) and the PLCs.
• Evaluate the extent to which the existing software is able to handle the new modules and sensors.
• If necessary, upgrade controllers or replace obsolete equipment.

Selection of a technology partner

• Whether you are implementing a new machine monitoring system or expanding an existing one, choosing the right solution provider is of paramount importance.
• Michale Automation specialises in the construction of customer-specific machines and production lines and the implementation of automation systems. If you are thinking of professional technical support, please see our section Service station maintenance, where we describe how we comprehensively maintain the equipment in excellent condition.

Phased commissioning

• Implement the monitoring system step by step. First select one line or a few selected machines to test the tools and data analysis model.
• Then expand the solution to other areas of the plant. This will spread the costs and risk of errors over time.

Machine monitoring versus efficiency - can the return on investment be quantified?

Investing in a machine monitoring system requires financial resources. However, by being able to accurately analyse operating costs, plan maintenance, reduce failure rates and reduce downtime, the investment more than pays for itself in the long term.

• Shorter downtimes mean greater production availability of machines, which translates into a higher number of units produced at any given time.
• Better quality results in fewer complaints or waste.
• For larger projects, it is worth estimating the ROI (Return on Investment) based on specific data on the current failure rate. If you would like to see what the investment calculation looks like when robotising one of your key processes, such as welding, visit our ROI calculator - Welding robotisation.

The most common challenges in machine monitoring

Although the effects of implementing machine monitoring systems are very positive, every company should be aware of several possible difficulties.

Integration of data from multiple sources

• Modern production lines are often a conglomeration of machines from different manufacturers. Each may use a different communication standard.
• The key is to bring all parameters together in a coherent system. This sometimes requires the use of dedicated gateways or rewriting of communication protocols.

Lack of human resources for data analysis

• Sometimes a company collects thousands of measurements per second, but there are not enough specialists who know how to translate this information into concrete conclusions and corrective actions.
• In such situations, it is worth considering training the team or working with a partner experienced in linking analytics to the production process.

Security and confidentiality of information

• Machine monitoring systems often have access to sensitive data (e.g. recipes, performance information and production plans).
• Implementation must comply with IT security policies. With a cloud model, particular attention must be paid to the data encryption standard and privilege management.

Machine monitoring - key recommendations and conclusions

1. Start with clearly defined goals. Determine which departments (production, maintenance, quality control) will benefit from monitoring and how.
2. Ensure a scalable data collection platform. IoT and Industry 4.0 solutions are developing rapidly, so it is crucial that your system can be easily expanded.
3. Invest in system integration. You will achieve the highest level of efficiency when monitoring is fully integrated with automation, robotics and master systems.
4. Remember to analyse the return on investment. Accurate calculations that take into account downtime reduction and quality improvements often appeal to decision-makers more than general technical arguments.
5. Consider implementing predictive maintenance. If you are already monitoring machine parameters, moving to a predictive maintenance strategy will be a natural step on the road to full digitalisation.

SUMMARY

Machine monitoring is not just a fad or an element of marketing associated with Industry 4.0. It is a real tool to reduce costs, reduce downtime and improve production quality and safety. By implementing monitoring, you give yourself the chance to detect problems quickly and optimise subsequent processes more easily.

In practice, this means that your company becomes more competitive and prepared for dynamic market changes. If you would like to learn more about the possibilities of automation and building complete robotic workstations, use the information in the Robotisation. It is also worth exploring Michale Automation's offer in terms of service support and process optimisation - for more details see Services.

Feel free to leave a comment with your own machine monitoring experiences. If you have additional questions about system integration, robot implementations or specific examples of solutions for your industry, please contact our team. Also, follow the company's blog so you don't miss further articles on the latest trends in automation and robotics for the industry.

By monitoring machines Your company can step up to a higher level of production efficiency and safety. Responding promptly to signals coming straight from your equipment is a simple way to increase your competitive edge in the market - both today and in the future.

FAQ

What machine parameters can be monitored?
Among other things, temperature, speed, vibration, energy consumption, pressure or motor load can be monitored. It all depends on the specifics of the machine and the key process parameters.

Does machine monitoring pay off for a small business?
Yes. Solutions have become more affordable in recent years and smaller businesses can also achieve noticeable benefits through reduced failure rates and better maintenance management.

Is it necessary to upgrade controllers before implementing monitoring?
Not always. However, it is worth carrying out an audit of the infrastructure to ensure that the current controllers and industrial network are able to work with the new monitoring system.