What is intelligent maintenance?

Intelligent maintenance combines data analysis with technology-enabled information gathering to make assumptions about potential failures and generate greater added value for the business. Unlike traditional approaches that focus on reactive repairs or scheduled interventions, intelligent maintenance is based on collecting and linking data from assets, plants or buildings to maximise operational efficiency.

The link between intelligent maintenance and Maintenance 5.0

Intelligent maintenance is closely related to the concept of Maintenance 5.0, an evolution that goes beyond automation and focuses on the integration of technologies such as the Internet of Things (IoT), artificial intelligence (AI) and machine learning.

While Maintenance 4.0 focuses on the digitisation of maintenance processes, Maintenance 5.0 seeks autonomy and adaptability of maintenance systems through artificial intelligence and human-machine collaboration.

Maintenance 5.0 follows a human-centred approach in harmony with software and hardware. It is increasingly customisable for each facility and piece of equipment, safer and more intuitive for technicians and less disruptive to normal operations.

An ebook on Maintenance 5.0

Benefits of intelligent maintenance

Reduced operating costs

By preventing failures and minimising unplanned downtime, intelligent maintenance helps reduce costs associated with emergency repairs and lost production.

Increased asset availability and operational efficiency

By constantly monitoring asset performance and predicting potential problems, intelligent maintenance ensures higher asset availability, which improves operational efficiency.

Resource optimisation

By scheduling maintenance tasks more efficiently and allocating resources according to asset priority and criticality, intelligent maintenance enables more effective utilisation of manpower, spare parts and labour time.

Improved strategic planning

By providing detailed data on asset performance and maintenance costs, intelligent maintenance facilitates long-term strategic planning and informed decision-making on asset and resource investments.

Increased safety

By proactively identifying and addressing safety issues, intelligent maintenance contributes to a safer working environment for employees.

Challenges of intelligent maintenance

Despite its many benefits, the adoption of intelligent maintenance also presents some challenges. These include:

Systems integration

Implementing technologies such as IoT and AI can require the integration of complex systems, which can be challenging for some organisations.

Staff training

Adopting intelligent maintenance often requires staff to become familiar with new technologies and processes, which can require significant investment in training.

Data security

With the collection and analysis of large volumes of data, concerns about information security and privacy arise, requiring additional data protection measures.

“There is no way to meet the challenges that Maintenance 5.0 brings without a human-centric approach, where software, hardware and people work together. But we cannot forget that the need to establish a more human-centred way of doing maintenance is a challenge in itself. We need to start thinking about collaboration as a means to work smarter and more resiliently, building stronger relationships that lead to lasting results. And this requires the use of smart technology”. — Luis Martins, Founder and CTO of Infraspeak

IoT in intelligent maintenance

The Internet of Things (IoT) plays a key role in intelligent maintenance by enabling the connection of assets and equipment through smart sensors.

Data Collection and Sensors

IoT involves connecting devices, equipment and assets to the internet, allowing them to communicate and share data. This connectivity enables real-time monitoring of various parameters such as temperature, vibration, humidity, pressure and energy consumption. These sensors provide a continuous flow of information, allowing maintenance teams to have a comprehensive view of asset health.

Remote Monitoring and Control

IoT devices facilitate remote monitoring and control of assets from anywhere with an internet connection. This capability is particularly beneficial for assets that are geographically dispersed or located in remote or hazardous environments.

Machine Learning

The vast amount of data generated by IoT sensors is analysed using advanced analytics techniques such as predictive analytics and machine learning algorithms. By analysing historical data and patterns, machine learning algorithms can predict when equipment is likely to fail, allowing maintenance activities to be proactively scheduled based on the actual condition of the asset rather than time-based schedules.

Condition monitoring and intelligent maintenance

Condition monitoring is an integral part of intelligent maintenance, as it allows real-time data to be collected and continuously monitor the condition of assets and detect any signs of deterioration or potential failure.

The data collected through condition monitoring is fed into advanced analytics systems, which are able to identify patterns, trends and anomalies that could indicate potential problems.

Infraspeak Gear™: intelligent maintenance starts here

Infraspeak Gear™ is an unique, intelligent core that processes your operational data to automate tasks and provide smart suggestions that have a real impact on your activities. It is an end-to-end solution, designed to optimise the maintenance and operability of equipment, machinery and other infrastructure in various industries.

Centralisation of Information

By analysing real-time and historical data, you can identify areas for improvement, implement corrective changes and continuously optimise your maintenance operations, contributing to the evolution towards a smarter and more efficient approach to maintenance.

Preventive Maintenance Scheduling

Infraspeak Gear™ allows preventive maintenance schedules to be established based on manufacturer specifications, expected asset life and historical data analysis. This feature ensures that maintenance activities are performed regularly and proactively.

Automate your work

Infraspeak Gear™ saves time and reduces human error by automating workflows and optimising resource allocation.