Predictive Maintenance 4.0 provides an average of nine percent uptime increase

A growing number of companies want to use big data analytics in their predictive maintenance and are also investing in the resources needed for this. Of the companies already using this technology, no less than 95 percent say that they have already achieved concrete results. This is the conclusion of a follow-up study conducted by PwC and Mainnovation in recent months, among 268 companies in the Netherlands, Germany and Belgium.

Predictive Maintenance 4.0 provides an average of nine percent uptime increase

Following the 2017 study into the maturity of companies in the field of predictive maintenance with big data analytics, Michel Mulders (partner and industry lead Industrial Manufacturing at PwC) and Mark Haarman (managing partner at Mainnovation) wanted to know to what extent companies have taken steps in the past year. Predictive maintenance with big data, level 4 within the maturity model, is called 'predictive maintenance 4.0' or PdM 4.0. PdM 4.0 makes it possible to predict failures that had been unpredictable up to now.

- We were interested to find out whether awareness of PdM 4.0 has grown, whether more use is being made of data, and in which areas investments are being made, says Michel Mulders. But also the reasons why companies do not start using PdM 4.0, and especially what results the frontrunners in this field are achieving with this technology.

95 percent of respondents indicated that PdM 4.0 is responsible for improving one or more key maintenance value drivers (uptime improvement, cost savings, reducing safety risks, extending asset lifetime). 60 percent of respondents managed to increase their 'uptime' with PdM 4.0, with an average improvement of nine percent.

The survey also shows that companies that achieve the greatest improvements in results thanks to PdM 4.0 clearly distinguish themselves from the other respondents. These 'PdM 4.0 champions' make significantly more use of 'environmental data' (such as weather conditions), characteristic of big data, and involve data scientists, reliability engineers and IT specialists in maintenance much more often.

Key findings

The study shows that, despite the fact that the number of companies using predictive maintenance with big data has remained stable, there are clear indications that many companies have the ambition to increase their maturity in predictive maintenance. 60 percent of the companies now indicate that they have concrete plans to use PdM 4.0, a significant increase compared to 49 percent in 2017. They clearly see the added value that PdM 4.0 can deliver.

More and more companies invest in competencies and personnel in order to get the most out of PdM 4.0. The research shows a sharp increase in the use of varied datasets, more advanced data sources and data software, data platforms and connectivity solutions. In comparison to 2017, there is also an increase in the number of data scientists, IT specialists and reliability engineers who are hired to realize the ambition to make full use of PdM 4.0.

Research report: Predictive Maintenance 4.0 - Beyond the hype: PdM 4.0 delivers results (link to report )

Asset Management | 25.9.2018

Latest articles

How ultrasonic sensors and artificial intelligence improve condition monitoring

In an industrial setting, assets are everything. A breakdown can cause hours  of downtime, and thus hours of lost productivity and lower financial gains. Preventative maintenance is one way facility managers counteract system entropy, but it is not perfect strategy. In some cases, a preventive approach to maintenance can actually lower the overall effectiveness of an asset. In the case of a valve for example, constant tightening can cause premature wear and tear.

Applications | 23.10.2018

To analyze or not to analyze, that is the question

Can we successfully improve reliability without analyzing reliability data?

Asset Management | 23.10.2018

Sustainability transformation: Are you ready for the change?

Companies which create truly sustainable businesses will remain competitive in the future.

HSE | 27.9.2018

Evaluating IT asset management software: Who do you trust?

Nowadays, more or less all companies have to deal with diverse kinds of IT assets. Using IT assets (software, hardware, digital media and networking) is no longer specific to the technology giants. 

Cmms | 7.9.2018

New methanol engine ready for the marine market

Within the frame of the GreenPilot project, Gothenburg-based ScandiNAOS AB has developed methanol engine concepts for the marine industry. A spark ignited methanol engine that wasn installed and tested in the Swedish Pilot boat “GreenPilot” has now been followed by a compression ignited methanol engine. The GreenPilot project is lead and initiated by Swedish Maritime Technology Forum, part of RISE Research Institutes of Sweden.

R&D | 4.9.2018

How to Safely Align Wind Turbines

Safety engineers around the world can breathe easy. The PRUFTECHNIK ROTALIGN® and OPTALIGN® technology has made aligning machine shafts, especially gear shafts, much safer.

Partner Articles | 6.6.2018

Maintenance: A Necessary and Important Function in the Future

Euromaintenance 2016 will take place in Athens at the end of May. It is the ideal moment to reflect on maintenance in a European context. Euromaintenance is known as the summit for all involved in maintenance across Europe, it’s the place to be. The conference, with the support of the EFNMS, is the only commercially independent conference covering the topics we deal with in the maintenance world.

EFNMS | 20.5.2016