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A fascinating future awaits maintenance technicians in the world of increasing access to artificial intelligence (AI), and other industry 4.0 digital advancements. A central question many industrial leaders are pondering is, “How will this technology shape our industrial world and the hands-on role of the maintenance technician?” We at Marshall Institute believe that a beautiful partnerships can exist between these technicians and AI. Admittedly, and understandably, past technological adoption and corporate initiatives have left many technicians wary of future advancements.

Our aim with this article is to illustrate several ways that partnership between techs and AI can lead to great outcomes. And in the process, we hope to allay concerns and boost excitement from technicians around the world.

Imagine the scene…you are a maintenance technician wearing your trusty toolbelt and armed with decades of hands-on experience. And, now, you have a new partner – AI. (Like ROBOCOP joining the Detroit Police Department.) It is not there to replace you or take over, instead it is the perfect supplement to your expertise. You are teaming up with a brilliant apprentice who can process data at lightning speed and make suggestions that might just save the day. How does that sound?

Farfetched? It might seem so, however, sci-fi fantasy is quickly becoming our industrial reality.

We understand the hesitancy amongst technicians to adopt new digital tools. Change is awkward when slow, but downright terrifying when at the speed of light. Of course, there is the age-old, and justified, concern about technology taking jobs. And we have not forgotten the painful memories and legacy headaches of other failed ‘silver-bullet’ technologies and forgotten flavour of-the-month initiatives. History shows that technicians have good reason to recoil at the sounds of phrases like “digital plant”, “AI”, “game-changing technology”.

Let’s change the narrative and excite our technicians. The following examples are just some of the opportunities for great partnership and enhanced technical output.

Preventive Maintenance

I am sure that everyone reading this article has strategic asset management plans, existing PM programmes, and a robust RCM/PMO programme. [Spoiler Alert} This is not the ‘norm’. Many plants around the world have assets that have been bought cheaply, installed hastily, and commissioned before being correctly added to the CMMS, before parts are identified, before a PM programme has been built, and before techs have been trained, etc. Now imagine, for the average industrial site, a world where you no longer wait for things to break before you fix them. AI crunches and analyses historical and real-time data and predicts when a machine is likely to give you trouble. It is like having a sixth sense that tells you, "Hey, that conveyor belt is acting a bit funky. You might want to take a look at it," allowing the technician to take action before disaster strikes, reducing downtime, and keeping operations humming along.

AI has the potential to greatly enhance a world-class manufacturing operation through its ability to add refinement and efficiency. By leveraging sophisticated algorithms and machine learning, AI can analyse vast amounts of data and constantly monitor and optimise processes. This can lead to improved productivity, reduced downtime, and enhanced quality control. AI-powered predictive maintenance systems can proactively identify potential equipment failures, enabling timely maintenance and preventing costly breakdowns. Additionally, AI can facilitate real-time inventory management, ensuring optimal stock levels and preventing stockouts or excess inventory. Overall, AI adds a layer of sophistication to manufacturing operations, enabling businesses to stay ahead of the competition and deliver consistent, high-quality products.

Troubleshooting

These days, at least in the U.S., good troubleshooters are in short supply! We have lost a lot of technical knowledge, and with it, troubleshooting capability. If this is the case for you too, imagine providing your apprentices, or less experienced technicians, with an AI tool that has access to a universe of technical manuals, past repair logs, and even real-time sensor data; it is like having a walking encyclopedia that whispers solutions in their ear. These techs will be backed by a digital brain that can analyse complex issues and recommend precise repairs at lightning speed.

AI doesn't steal your thunder; it enhances it! Instead of replacing your skills, it amplifies them. It empowers you to make more informed decisions and tackle challenges that might have seemed impossible before.

Collaboration

Our belief is that the future is not just about machines and systems, it is about collaboration between people and tools, as it always has been. Imagine a scenario where a technician hits a roadblock when working on a complex piece of equipment. Instead of doing it alone, they can now tap into a global network of experts through AI-powered platforms. It is like having a team of colleagues at your fingertips, ready to jump in and lend their insights. They are no longer isolated in your workshop; they are part of a community of problem-solvers now, which they can both benefit from and contribute to!

Continuous Learning & Development

As this connected ecosystem of people, devices, and information matures, continuous learning becomes your superpower. Imagine if every solution you come up with and every tweak you make gets recorded and fed into the AI system. Human and AI partnership is like building a knowledge warehouse that never forgets, or requires coffee to remember. Over time, your AI companion learns from your experiences, and those of other technicians, becoming smarter and more capable with each issue it helps you solve.

The best organizations are world-class learners and people-developers. But we know that a commitment to developing people takes focus, time, and budget. As AI takes care of the repetitive and routine tasks, you will have more time to dive into advanced training and new technologies. It is like getting a chance to boost skills and become masters of their craft.

Closing Thoughts

Although my colleagues and I at Marshall Institute are optimistic about the future, I want to be clear that I am not suggesting that AI, and other Industry 4.0 tools, are standalone solutions to our reliability challenges. Tools do not create performance, they enhance it. So, it is our responsibility to ensure that the foundations of “asset management house” are sound before we build up. Part of this digital transformation is appropriately understanding the use and value of these tools and communicating their use and value to those most impacted. If we do this right, we can reduce fear, and maybe, just maybe, get technicians a little excited.

We believe that if we transition to the digital plant effectively, maintenance technicians will be stepping into a world where AI can be their trusted sidekick. It is a world of enhanced troubleshooting, predictive prowess, continuous learning, collaborative networks, and personal growth. The tools we use might be changing, but the heart of a technician – that unwavering dedication to keeping things running smoothly – remains at the centre of asset reliability.

Text: Alan Warmack, Director of Training Services - Marshall Institute, Inc. | Image: Freepik