Predictive maintenance uses real-time data, IoT (Internet of Things) sensors, and advanced analytics to predict equipment failures before they occur. Unlike preventive maintenance, which follows a fixed schedule, predictive maintenance is based on real equipment conditions, allowing for a more accurate and efficient approach.

Benefits of Predictive Maintenance

1. Reduction of Unplanned Stops
   • Continuous Monitoring : IoT sensors monitor equipment performance 24/7, identifying signs of wear or imminent failure.
   • Proactive Intervention : Data analysis allows maintenance teams to intervene before a failure occurs, preventing unplanned downtime that could disrupt production.
2. Increased Useful Life of Equipment
   • Condition-Based Maintenance : Maintenance is carried out only when necessary, based on the actual conditions of the equipment, extending its useful life.
   • Resource Optimization : By carrying out maintenance only when necessary, resources are used more efficiently, saving time and money.
3. Improvement in Product Quality
   • Regulatory Compliance : Predictive maintenance helps ensure that equipment is always in optimal condition, complying with the pharmaceutical industry's strict regulatory standards.
   • Consistency in Production : Well-maintained equipment produces more consistent results, ensuring the quality of the final product.
4. Reduction of Operating Costs
   • Maintenance Savings : Predictive maintenance reduces the need for emergency repairs, which are generally more expensive and time-consuming.
   • Waste Minimization : Equipment that works efficiently produces less waste, optimizing the use of raw materials and other resources.

Implementing Predictive Maintenance

1. Installation of IoT Sensors
   • Choosing Suitable Sensors : Select sensors that can monitor critical parameters such as temperature, vibration, pressure and humidity.
   • Integration with Existing Systems : Ensure IoT sensors can integrate with existing IT systems such as ERP and the Oran+ platform for centralized data analysis.
2. Data Analysis and Machine Learning
   • Data Collection and Storage : Use IoT platforms to collect and store large volumes of data generated by sensors.
   • Machine Learning Models : Develop machine learning models that can analyze collected data and identify patterns that indicate imminent failures.
3. Team Training
   • Technical Training : Provide training to maintenance and operations teams on how to interpret data and act on predictions.
   • Culture of Continuous Improvement : Encourage a culture of continuous improvement, where the team is always looking for ways to optimize the maintenance and operation of equipment.
4. Integration with Maintenance Plans
   • Maintenance Planning : Integrate predictive maintenance forecasts into existing maintenance plans, adjusting schedules and prioritizing data-driven interventions.
   • Continuous Assessment and Adjustment : Conduct regular assessments of the effectiveness of predictive maintenance and adjust strategies as needed to improve results.

Success Stories

Case Cristália: Oransys implemented smart sensors for continuous monitoring of Cristália's production equipment, allowing real-time analysis. This innovation significantly improved efficiency, reduced costs and optimized decision making, generating notable gains in production. Check out Cristália

União Química Case: União Química implemented a solution integrating IoT, Cloud Computing and Advanced Analytics, which increased production capacity by 20% and reduced costs by 8%. This advance positioned the company at the top of innovation rankings in the pharmaceutical sector. Find out more about this success

Predictive maintenance is an evolutionary approach for the industry, offering numerous benefits in terms of operational efficiency, product quality and cost reduction. By implementing IoT sensors, advanced data analytics and staff empowerment, companies can transform their operations and gain a significant competitive advantage.

At Oransys, we offer advanced solutions that can help your business achieve these goals. Contact us to learn more about how we can support your journey to operational efficiency.

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