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Predictive Maintenance: The Next Frontier in Manufacturing

In industries where equipment failure is one of the largest causes of downtime, manufacturers must find solutions that prevent lengthy and unplanned downtimes. Why? Unplanned downtime can destroy their ability to be competitive in the market. Traditional solutions to handle these downtimes are either replace the parts before their end of life comes up by making calculated guesses, or predict downtimes based on past occurrences. Unfortunately, both solutions are not a perfect fit and can be cost-intensive and very risky on the manufacturer’s end. The current trend of maintenance requires a tradeoff, whether it be reactive, planned, or proactive, whereas, in the predictive maintenance era, this will not be required.

Why Do traditional solutions have tradeoff?

Due to how limited traditional solutions are, they have quite a few tradeoffs when utilizing them. For instance, if a manufacturer wants to be reactive to downtimes, they must understand when their machine parts will hit maximum utilization. At max utilization, the whole machine can become damaged and result in the downtime.

On the other hand, if a manufacturer wants to plan for the downtime and not risk the breakdown of their machines, they must replace parts before their end of life, with the tradeoff being increased part replacement costs. To be proactive in protecting themselves from unplanned breakdowns, one must increase maintenance costs to extend machine part life. As we can see, these tradeoffs are not necessarily cost-effective or foolproof solutions. With predictive maintenance, these tradeoffs are eliminated as it minimizes downtime and backs up proactive maintenance with data so that costs can be maintained.

How does the Internet of Things work with predictive maintenance?

When you attach the Internet of Things to a physical asset like a manufacturing machine, you create a cycle between the IoT device and the physical machine. This cycle works on a physical to digital and back to physical cycle, meaning your physical asset provides digital data to the device, which creates a physical solution.

Here is how it would work.

An IoT device with sensors is placed onto the manufacturing machine. The sensors generate data that pertains to how the machine is functioning.

The generated data is digitized and analyzed for insights. This could be analyzing information about part breakdown percentages, parts that are not working correctly, or even data on the end of a specific part of the life cycle.

These insights are relayed back to the machine and physical actions, like replacing parts can be taken.

Essentially, this IoT enabled cycle allows organizations to take actions based on real-time data, making companies more agile in their response times and creating smoother operations with minimized disruptions.

How does predictive maintenance ensure smooth operations?

While the major benefit of predictive maintenance is the ability to identify and manage risks that are associated with machine downtimes, it can be used across a wide variety of industries that require the assessment of operational data.

Here is how predictive maintenance ensures that a smooth operation occurs.

By using a combination of science, math, and engineering principles, predictive maintenance brings dependability and efficiency to the productive process and all products within that process.

Predictive maintenance can analyze multiple operational data sources and types. It can generate and analyze real-time data, batch-data, structured or unstructured data, and even at rest or streaming data components.

By using data from IoT enabled devices, the predictive maintenance model can be continuously improved upon, factoring in other types of data generation points like motor circuits, vibrations, and thermography.

Predictive maintenance can create a data-based multivariate metric that provides manufacturers with information on end of life or remaining life for parts. This is statistically significant because it removes the guesswork that is used with traditional methods.

Which industries can be impacted the most with Predictive maintenance?

1) Structural Infrastructure:

In countries where infrastructure is in dire need of repair, predictive maintenance can aid in helping construction crews know what needs to be repaired when and why. For instance, things like bridges, sewers, and highways that go unrepaired for long periods can have dire consequences on the population, but if a predictive maintenance model is used, disasters can be avoided, and costs controlled.

2) Automakers:

One always hears about the vehicle recalls, which is not only annoying for customers who have these vehicles, but it poses quite a dangerous risk to those who have vehicles being recalled for serious issues. If automakers were to use data and machine learning from predictive maintenance, issues could be uncovered during the design and roll-out phases, preventing major recalls.

3) Oil & Gas Production:

There are millions of pipelines that traverse countries with the sole purpose to transport oil and gas. Many of these pipelines were constructed decades ago, resulting in the deterioration from overuse and aged materials. As these pipelines get older, there is a much higher likelihood that failures will increase. Being able to predict and prepare for these situations can avert major disasters.

4) Airline Maintenance:

When it comes to airline maintenance, it can get complicated very quickly due to how vast the aviation industry is. It may take several teams to understand why a specific part is in disrepair. Predictive maintenance offers a safer and simpler solution that is economical.

Is Predictive Maintenance Possible?

Yes, predictive maintenance is technically possible, and it is currently technically accessible as well. Companies do not need to make massive investments into acquiring the predictive maintenance model because the data that is needed to be proactive about maintenance is already available. It just needs to be captured, stored, and analyzed. The first step in making it happen is connecting machinery to IoT sensors so that real-time data can be tracked. This data should then be fed into a network where it can be stored and processed in large volumes. Once the data is gathered, anomalies and patterns should be tracked, and corrective action should be taken based on data insights.

Let’s Nurture – the best IoT app development company provide expert consulting to help Companies not to make massive investments into acquiring predictive maintenance. Our expertise in providing IoT based solutions has helped us in developing a Smart Automotive Solution, KarConnect, on Web and Android platforms.

Let’s talk and build innovations around us!

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Top 5 Generic Diagnostic Codes & How OBD apps like KarConnect can help you to resolve it?

According to Statista, “Every year the lives of approximately 1.35 million people are cut short as a result of a road traffic crash. Between 20 and 50 million more people suffer non-fatal injuries, with many incurring a disability as a result of their injury.”

This may be due to improper functioning of the vehicle or rash driving behavior. As these consequences also affect the country’s overall GDP growth along with personal losses, an IoT based automotive solution is the primary need to bring that level of awareness with car/ vehicle safety.

Importance of on Vehicle Diagnostic Systems:

Implementation of OBD-ll became mandatory after 1996 for all cars. As a result, all light-duty truck and medium-duty vehicles are having OBD-II port integrated. It helps to check emission, fuel economy, low-performance indication, and scores of other minute issues. Before Implementation of OBD-II, drivers were bound to visit garage physically with their vehicle to fix even the small faults and waste a lot of time. It invariably resulted in decreased efficiency of fleet operations.

Moreover, It is always very expensive to pay repair bills in the absence of OBD reader. In addition, The Driver should be knowing the vehicle’s technical aspects as modern vehicles are not easy to repair. The OBD scanner tools have turned it into budget-friendly and time-saving solution with the possibility of self-diagnosis and immediate reporting on malfunctioning of the specific component. It eliminates unnecessary repairs with complete information.

For instance: When the vehicle engine is malfunctioning, the driver might think that it’s time to tune the engine, but perhaps, the system just needs oiling. When the driver gets the same information on the dashboard and reads it with the OBD-ll scanner, they can easily pinpoint where the problem is and find out whether it’s in their control to fix or not. When the faults are minor, they can be fixed easily at a low cost than rushing for an authorized service center or garage.

The list of Top 5 generic codes which can be detected using an OBD Sensor.

OXYGEN SENSOR.

ENGINE MISFIRE.

EVAPORATIVE SYSTEM.

EXHAUST GAS RECIRCULATION (EGR)

CATALYTIC CONVERTER.

Why OBD2 based Vehicle Diagnostic App is needed?

Accidents

Road Accidents are caused by two basic factors – improper driving and non-maintenance of vehicle. These road accidents cost $518 billion globally, costing individual countries from 1-2% of their annual GDP. With KarConnect, we aim to save those numerous lives and build a better global economy by reducing the loss of GDP.

Expensive diagnostic sensors in the market

There are few big brands available in the market like Bosch which reads codes and find the fix. Scans tools range from simple code readers to advanced diagnostic tools featuring live engine data, ABS and Airbag coverage. However, such tools are very expensive and everyone can not afford it. KarConnect, an IoT based automotive solution developed by Let’s Nurture, is an affordable and ultimate solution to this.

Prediction through low, medium and critical fault codes

Our Product KarConnect can give you details about fault codes (self-diagnosis) which can avoid a potential breakdown of the car and accidental damages. The application gets you the list of all Service Centers nearby live location. KarConnect also provides real-time tracking of the vehicle condition and driving behavior remotely. So, the product is equally useful for both businesses and individual drivers/owners.

Read More: Cost to develop ELM OBD-II based Car Diagnostic Application

Why Karconnect is the Ultimate Solution (OBD-II App)?

Our expertise in delivering custom IoT app development services has helped us in developing a Smart Automotive Solution (KarConnect) on Web and Android platforms. Along with Real-time tracking, this Android app helps you to understand the health of your car, driving behavior and fault detection in multiple local languages, for your vehicle(s). The web app allows you to remotely monitor your vehicle(s) along with the driving pattern of the driver. This custom built IoT app solution also offers emergency roadside assistance and can find nearby service centers.

KarConnect is the key to unlock the world of Connected Cars. It is a smart technological combo of two components – 16 Pin OBDII Chip (Hardware) and mobile application (Software). KarConnect Device is plugged in your car’s OBDII port, fetches data from the ECU (Electronic Control Unit), do data crunching and send it to the server for further analysis. The application will receive insights from the KarConnect device detailing you with seamless reports and predictive alerts.

Develop your own Custom Car Diagnostic Application

It’s an initiative to make your driving not only smart but safe. ‘Safety first’ is the motive of this product. KarConnect uses OBD-II (Onboard Diagnostic) Chip hardware, that helps in fetching the car data in order to provide you endless solutions which can be used to tracking, streamlining and controlling the operations along with vehicle maintenance.

Smart Vehicle Diagnosis

Reduce Fleet Maintenance

Improve Fuel Efficiency

Predictive Maintenance

Asset Tracking Solutions

GPS/Geofence based Tracking

Supply Chain Management Solutions

Emergency Roadside Assistance

Nearby Service Centers search via Google Maps

Alerts for Service and Maintenance

SOS/Emergency Alerts System

Multilingual language for fault codes

White Label solutions for Web and Android app development

Why we are the ideal partners for Car Diagnostic App Development?

Let’s Nurture is a leading ISO 9001:2015 certified IoT solutions providing company offering smart solutions for multiple industries. We offer a white label solution similar to KarConnect depending upon the customer requirement by adding features like geofencing, remote engine auto-lock, etc. We hold expertise in providing custom white-label automotive solutions that can be helpful for smart fleet management operations too.

We also can help you with a custom website app development for the same where customers can manage fleet and track vehicle data, maintenance costs and more. Our quality driven process will give you a fully functional, responsive and flawless user-friendly Vehicle / Car Diagnostic application that will incorporate all the features you want using the latest technologies.

Talk to our industry experts to know more on White-label automotive solutions like KarConnect.

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How IoT & Blockchain will impact Automobile After-sales Industry

Cars of 21st century represent not only a mode of transportation, but they also present innovations and technology on wheels.

We are living in an era of technology and solutions all around us. As v12data reports that the global automotive aftermarket industry is expected to reach $722.8 billion by 2020, we are having a look upon two the most popular technologies- IoT & Blockchain. Leveraging IoT and Blockchain, let us have a look at the diverse solutions and applications which can be implemented for automobile after-sales market to enhance operations, better quality of service (QoS) while decreasing the overall costs.

Need of Robust Solutions for Tech filled Automobile Industry

The automobile industry is enormous with multiple segments ranging from manufacturers, dealers, service centers, auto finance companies, OEMs and retailers of auto parts and so on.

The grueling thing is that these segments are poorly integrated due to a lack of ecosystem resulting in operational inefficiencies from shop to the top and the costs incurred are being beared by the car owners along with ride-sharing users as a whole. This created a lack of trust and transparency in the used car market. Also, the grey market in automobile after-sales segment selling fake products is huge and car owners are bearing this pain.

The automotive industry is one of the world’s most technologically advanced production sectors, and its associated markets are incredibly broad, ranging from vehicle sales to auto insurance to car repairs, and the list goes on and on. However, these markets are still highly segregated, leaving the participants to deal with extreme inefficiencies that lead to excess operating costs and inflated prices.

IoT solutions for automobile after-sales market

Emergence IoT technology has brought us to a stage where seamless solutions are being built around multiple industries. Automobile after-sales is no isolation in this regards too. IoT based solutions have transformed not only cars to Smart Cars, but also have resulted in an ultimate shift in transforming garages to go ‘Smart’. Hence, let us have a look at how IoT has impacted the after-sales market with Smart automotive solutions.

IoT based Remote Diagnostic Solution for Garages

A garage or service center is at the core of the automobile after-sales market. The problems of the conventional garages are to wait for the customers, lack of visibility, identification of the problem before finding the solutions resulting in decreased efficiency.

Leveraging IoT app development, garage owners can have their records for their registered customers and track the device if the customer agrees to share some personal bit of information about the cars. By building custom garage apps, the service stations can digitally record vehicle maintenance data for future reference. This saves a lot of time while diagnosing the vehicle in the future.

IoT based solution for Insurance Companies

When a user installs a tracking device into OBD ports of their cars, it sends data. What data, you may ask? Well, whatever information your insurance company deems relevant to determining whether or not you’re a good driver. This data is sent back to your insurance provider.

Read more: How Installing OBD Devices like KarConnect can improve your car insurance premium?

Based on the improved driving behavior and data carried out from the predictive analysis on preventive maintenance, insurance companies can attract their customers with some improved plans or reward points to make them loyal to an auto insurance policy.

Blockchain Technology for Automobile after-sales market

Blockchain has been prolific due to its following benefits:

unparalleled security

execution speed

transparency

cost reduction

ability to audit records

Versatility

Automated Digital Vehicle Maintenance Book for Authorised Service Centers

The first prototype of vehicle maintenance book is announced by Renault last year, in conjunction with Microsoft and consulting company called VISEO. For second-hand cars market, it will cater automated automobile transactions with complete transparency and security as owners and dealers share vehicle history with the potential buyers. This system can also be used by the insurance companies to set rates accordingly to offer a monitored auto insurance policy to their own customers.

Blockchain facilitates Autonomous Ride Sharing

On-demand taxi booking and ride-sharing applications like Uber and Lyft are bringing more innovations to change the way of vehicles being used. Leveraging Blockchain development, this can turn to reality. Tesseract is the Blockchain System launched by Ernst & Young in 2017. This facilitates autonomous sharing of not only the rides but also vehicle ownership. This can be a perfect solution for the fleet management companies to manage the entire autonomous fleet of vehicles. The payments will automatically settle by the system with utmost transparency.

Blockchain Automates Controlled Interactions

Imagine a car could advise the drivers about the need for a repair. Sounds like IoT, right? Yes, it does. However, by the implementation of blockchain ecosystem, this platform can be taken to the next level. Leveraging blockchain technology, drivers can contact remote users of the blockchain ecosystem for updates, nearby suppliers for remote part availability, negotiations in pricing. Even garage owners and service centers can be contacted to fix appointments for service repairs the following access to make payments.

There are millions of devices in the automotive industry communicating with each other and hence, a shared database platform is needed where all this information can be stored in the most secured manner with control over the accessibility.

Blockchain as an Add-On to Vehicle Infotainment Systems

From the car owners point of view, everyone is attracted to the innovations which are pitching in to enhance the driving experience. Today, vehicle infotainment systems can be considered on the same level as the home entertainment systems. Even technology applications like Apple’s CarPlay can do everything that an iPhone does.

Blockchain can be an amazing add-on to infotainment segment in this scenario. Leveraging Blockchain, due to its reliability and transparency in transactions, users can make secured in-car payments instantly for the media content and other services they wish to have.

What the Future Holds with such Technologies?

IoT and Blockchain solutions can stage endless possibilities ranging from a safer and eco-friendly driving behavior, enhanced and favorable auto insurance policies, remote locking and unlocking of the vehicles and more. I am sure the limit is not up to what I have discussed through this article.

Are you looking for best IoT services and Blockchain solutions? Let’s start a new project together.

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