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Introduction

Picture this: you are standing on the production floor of your factory amidst the clamping and cluttering of machines, which may be a symphony to your ears when suddenly you hear a not-so-pleasant sound, a sputter and a machine breaks down. This may most definitely not be music to your ears; to you, it means missed deadlines, decreased earnings, and increased worry.  According to Deloitte, predictive maintenance lowers maintenance costs by 25%, decreases breakdowns by 70%, and increases productivity by 25% on average. The possibility of unanticipated failures haunts every manufacturer. What if you could change the script? Introducing predictive maintenance, a data-driven oracle. Enter PTC ThingWorx – an IIoT platform to build custom solutions quickly custom to your requirements.

PTC ThingWorx platform ensures that your production works efficiently and deadlines are met on time. Forget about severe deadlines and blind fixes. ThingWorx converts your factory into a network of connected machines that whisper secrets via sensors. It detects anomalies before they become disasters, predicting breakdowns with exceptional accuracy.

ThinkWorx platform provides alerts before faults occur. It examines your machines’ whispers to predict problems with surgical precision. With ThingWorx you’ll be able to:

  • Schedule maintenance like a pro: ThingWorx removes calendar uncertainty by providing exact remedies.
  • Extend machine life: Early detection prevents calamities and keeps your equipment functioning.
  • Exponentially reduce costs: Avoid the bottomless pit of downtime and save significantly on repairs and lost productivity.

The future is here, and problems are but footnotes. ThingWorx is the gateway to a future where foresight is your weapon. In this article, we shall go over how you can leverage PTC ThingWorx along with ThingWorx partners in India like Pratiti Technologies for predictive maintenance and usher in a new era of optimised operations and limitless possibilities.

Understanding ThingWorx for Predictive Maintenance:

With ThingWorx, an IIoT platform, leading the predictive maintenance revolution, you can imagine your factory’s machinery expressing its health and performance in real-time. Its core functionalities form the backbone of intelligent insights:

  • Data Acquisition: ThingWorx collects data from various embedded sensors in your equipment, such as vibrations, temperatures, and energy usage, efficiently. These real-time data play a major role in your prediction models.
  • Connectivity: It bridges the gap between humans and technology by serving as a translator. Systems can easily exchange operational data, which encourages data scientists and engineers to work together.
  • Analytics: ThingWorx analyses this data using AI and machine learning algorithms to identify patterns and anticipate issues before they arise. Think about a broken gear several days before it breaks, not when the production line stops.
  • Visualisation: Data is displayed in simple, actionable dashboards. You can monitor the health of your whole plant at a glance, identifying areas that require care and optimising maintenance plans.

But why choose PTC ThingWorx over other platforms? Its distinct advantages push it to the forefront of predictive maintenance:

  • Flexibility: Work smoothly with current systems and equipment, independent of OEM vendors. No more siloed data, just one unified picture of your operations and innovation services.
  • Scalability: From a single machine to a global network, ThingWorx scales seamlessly as your predictive maintenance journey progresses.
  • Sector-Specific Solutions: Use pre-built templates and best practices for your sector to speed up your journey to predictive maintenance success. ThingWorx speaks your language, whether it’s oil and gas, discrete or process manufacturing, energy and utilities, solar or wind farms.

Implementing Predictive Maintenance with ThingWorx:

Ready to outsmart breakdowns? This is a step-by-step approach to establishing predictive maintenance using ThingWorx.

  1. Prioritise and connect:
  • Identify the important assets: Analyse failure history and choose equipment with a high impact potential for monitoring.
  • Integrate sensors and existing data sources with ThingWorx to collect real-time data streams.
  1. Predict and Monitor:
  • Create Models: Use ThingWorx Analytics (the machine learning techniques like regression, anomaly detection, etc.) to forecast possible problems.
  • Visualise Insights: Use dashboards and visualisations to monitor equipment health, detect anomalies, and track model performance.
  1. Automate And Act:
  • Trigger Actions: Create automatic notifications and work orders based on projected failures to ensure timely maintenance interventions.
  • Optimise and iterate: Continuously monitor and adjust your models, utilising ThingWorx tools and capabilities to increase accuracy and effectiveness.

Best practices:

  • Focus on data quality: To make credible forecasts, ensure that data is collected accurately and consistently.
  • Select the correct model: Choose the method that best matches your data and failure kinds.
  • Integrate with the current systems. Connect ThingWorx to your maintenance routine to ensure seamless action.

Navigating the Skies: Vestergaard’s Flight to Efficiency with ThingWorx Predictive Maintenance

In response to the important problem of probable failures, Vestergaard, a well-known aircraft service truck manufacturer, embarked on a revolutionary journey, deploying PTC ThingWorx for predictive maintenance. Faced with the risk of a 30% loss in airport capacity owing to truck breakdowns, Vestergaard recognised the need for a more complex solution than their decade-old Data Transmission System (DTS). With ThingWorx partners in the US, Germany and many other countries, Vestergaard chose to go with a ThingWorx partner in Finland. Together with Econocap, they chose ThingWorx as the Industrial Internet of Things (IIoT) platform to accelerate their maintenance strategy into the future. The IIoT-based solution, which manages up to 230 data points per vehicle, provided real-time analytics and predictive insights, resulting in a significant reduction in downtime and overall operational efficiency.

With hundreds of vehicles sharing data effortlessly, Vestergaard’s maintenance routines saw a significant improvement. Jacob Kildegaard, Manager of IT Engineering, praised the transformational impact: “ThingWorx has transformed our maintenance approach; we fix issues before disruptions, ensuring operational continuity.” This case study demonstrates how Vestergaard’s strategic deployment of ThingWorx addressed crucial difficulties and established new standards for operational efficiency, cost savings, and dependability in the aviation sector.

Conclusion:

Imagine a future in which breakdowns are whispers, not roars. Where your factory sings in perfect harmony, efficiency reigns supreme and costs fall. This is not fiction; it is a reality made possible by PTC ThingWorx and Pratiti Technologies: a top IoT solution provider.

ThingWorx is more than just an innovation services provider, it’s a revolution. It seamlessly connects your machines, gathers their whispers in the form of real-time data, and analyzes them with uncanny precision.  Forget reactive repairs – ThingWorx empowers you to predict and prevent, maximizing uptime and slashing costs. Are you prepared to join this cost-cutting revolution? Pratiti Technologies is your guide.

Don’t simply ponder over cost reductions; make them a reality. Contact Pratiti Technologies now. Let’s unleash ThingWorx’s full potential and catapult your business to new heights of efficiency and profitability.

Nitin
Nitin Tappe

After successful stint in a corporate role, Nitin is back to what he enjoys most – conceptualizing new software solutions to solve business problems. Nitin is a postgraduate from IIT, Mumbai, India and in his 24 years of career, has played key roles in building a desktop as well as enterprise solutions right from idealization to launch which are adopted by many Fortune 500 companies. As a Founder member of Pratiti Technologies, he is committed to applying his management learning as well as the passion for building new solutions to realize your innovation with certainty.

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