Reliability Matter 1.3 – Wireless Surveillance Systems Part 2

Wireless Surveillance Systems – Part 2

What is the Impact of INDUSTRY 4.0 and COVID-19 on Continuation of
Equipment Surveillance Systems?

Prior to COVID-19 the focus on equipment monitoring was growing to the extent that
specialists were routinely attending at manufacturing plants to perform route-based vibration
signature analysis, ultrasound greasing programs and other reliability CBM practices.

With COVID-19 – almost all of those activities came into question as manufacturing plants
were forced to question who was coming into their plants and for what reasons.

Add to this, the push to digitization under the banner of INDUSTRY 4.0 and the world as we
knew it changed overnight.

BUT, the reality is that equipment still needs to be monitored and somehow the condition of
equipment still needs to be maintained. No-one wants to return to the old days when
equipment was allowed to run to failure. Strangely, production demands in most
manufacturing environments are increasing, product shortages have been reported and
“UPTIME” demands have never been greater.

So how do we move forward with equipment monitoring when we no longer can allow
outsiders and our contractors to enter the building and spend time or at a minimum allow
attendance through a more controlled form of access.

Wireless vibration and process sensors are now available at a very reasonable price. These
new sensors offer more feature rich surveillance capability than what has been available in
the past and they are often more reasonably priced than the investment of manpower to
perform route based condition monitoring.

Check out WISER 3X wireless transducer with Digivibe MX30 and the On-Line wireless
sensors and system called PHANTOM that also uses the Digivibe MX30 software platform.

What are the Return on Asset (ROA) Considerations with a Wireless Surveillance System?

MANPOWER – The Costly Side of Condition Monitoring – Under the old system you were
paying for the technician to attend to your plant to inspect each asset, capture a vibration
signature and develop a report of their findings.
With a wireless surveillance system, the data is collected more frequently, communicated
automatically to a remote server, and the technician spends their time analyzing the data and
The benefits include

  • Increased equipment surveillance with data collection ranging from 10 minutes to once
    per day (as opposed to a route that occurs once each 4 weeks).
  • Reduced outside manpower intrusion into your plant. This may impact your own
    manpower availability as you will not need to escort the technician for the time he is in
    your plant. Safety protocols, safety awareness and safe access to sensitive areas of
    the plant are now completely controlled and limited to existing plant personnel.
  • More surveillance may lead to early capture of changes to machinery. This as
    compared to a 4-week snapshot generated by a route-based schedule of monitoring
    vs a daily stream of data that may catch a change between the traditional cycle of
  • Improved equipment uptime. On-line surveillance provides confidence that surprises
    will be identified and mitigated before an event shuts down production.
  • There is ample evidence that employee health and safety improves and safety costs
    decrease when surveillance and condition monitoring increases.

Can we help you with your system or give you a demonstration?

DTM Consulting Services is a company of equipment reliability technical specialists. We are
available to answer your questions

Ready to elevate your performance?

Contact Us