Research report: Predictive Maintenance 4.0

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 among 268 companies in the Netherlands, Germany and Belgium.

Research report: Predictive Maintenance 4.0

Following the 2017 study into the maturity of companies in the field of predictive maintenance with big data analytics, PwC’s Michel Mulders 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 four 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. 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, says Michel Mulders, partner and industry lead Industrial Manufacturing at PwC. 

Ninety-five 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). Meanwhile 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

Despite the fact that the number of companies using predictive maintenance with big data has remained stable, the study shows that there are clear indications that many companies have the ambition to increase their maturity in predictive maintenance. Sixty 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. 

Text: Nina Garlo-Melkas

PdM 4.0 as a service

There are reasons to expect ‘PdM 4.0 as a service’ to become increasingly important, in particular for OEMs. For instance, consider the ‘power-by-the-hour’ business model adopted by some manufacturers of jet engines. Rather than selling jet engines as a product, these manufacturers sell its output – namely the power it generates - as a service, which obviously gives them a major incentive to improve reliability and uptime.

Continuous improvements in the digitization and connectivity of industrial assets are allowing their performance to be monitored remotely. As a result, OEMs that collect asset performance data from their customer base will have access to much richer data than is available to individual users of these assets. In turn, this gives these OEMs a distinct advantage when it comes to predictive analytics. 

- We can thus speculate that OEMs will want to tap into this advantage by offering PdM 4.0 as a service, and that goals like ‘New revenue stream’ and ‘Better product design’ will become increasingly important value drivers for PdM 4.0, Mark Haarman, managing partner at Mainnovation says.

Asset Management | 17.1.2019

Latest articles

12 Helpful Tips for Doing IT Service Desk

Over the years, the evolution of technology and the adaptability of the people to it, has been increasing drastically. This process has brought about a boom in the service sector, making the IT subunit of it, the most successful.

Cmms | 27.12.2018

Change Management Best Practices

Change is inevitable in the process of evolution. With the kind of dynamism involved in the organizational structure and the current trends in the service sector, the need for a change has become increasingly important from time-to-time. Any organization that is moving towards an ambitious target, is bound to undergo appropriate changes at different levels in order to rejuvenate itself along with all its stakeholders and prepare for the journey ahead. This change will help the enterprise to take the much-required paradigm shift that can drive them towards higher ambitions and greater success. This reinstates the potential of bringing about a change in an organization.

Asset Management | 27.12.2018

It’s About “Time”

At Bentley Systems, we have been talking to our users, especially owners, and it has become clear that despite our collective best efforts, there is a gap in the market.  Owners need easy access to real-time, accurate, engineering information and they need tools that make it simple to keep engineering data up-to-date, especially those engaged in brownfield and revamp projects.  It takes too much time and effort to gather and verify the information they need to make decisions effectively. And for older plants that do not have 3D models, there is simply no visual way to verify and check information easily.

Partner Articles | 10.12.2018

How to Choose an Air Compressor, According to Science

Buying an air compressor, for the first time, can be challenging in many ways. There is a lot going on behind this power tool that offers faster and more efficient performance. Before we get to know about the details of an air compressor then, let’s understand how it works. How do air compressors work?

Applications | 10.12.2018

8 Ways to Identify and Eliminate Noise Hazards in the Workplace

Occupational noise hazards are one of the most common workplace safety concerns. Our hearing is sensitive and it does not take much to temporarily impair or permanently damage it. 

HSE | 10.12.2018

Bacterial Bandages, Natural Dyes and Recycled Fibres: Aalto Brings Materials Revolution to Slush

New materials play an important role in sustainable development and combatting climate change. New uses for old materials can also be a major industrial opportunity: for example, the value of biomass from forests in Finland can be doubled if used for manufacturing products of higher added value.

R&D | 4.12.2018

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