Predictive maintenance technologies in manufacturing
Manufacturing is entering a transformative era where technology-driven solutions are redefining how factories operate. Efficiency is no longer about merely maintaining production quotas—it’s about predictive insight, sustainability, and operational resilience. Predictive maintenance technologies, powered by the Industrial Internet of Things (IIoT), is a cornerstone of this transformation. It turns real-time data into actionable strategies that keep machines running efficiently and sustainably.
At the heart of this shift lies virtual twins, a technology championed by Dassault Systèmes through its DELMIA solutions. These dynamic digital replicas bridge the gap between the physical and virtual worlds, enabling manufacturers to simulate, optimize, and refine their operations like never before.
Understanding MOM and MES
Manufacturing Operations Management (MOM) software encompasses a broad range of activities that support production, including quality management, logistics, materials management, time and labor, and maintenance. MES is a key component of a MOM strategy.
MOM and Manufacturing Execution Systems (MES) software are critical to modern manufacturing but serve distinct roles. MES operates on the shop floor, directing labor and materials, collecting real-time data, and ensuring production efficiency. MOM, however, takes a broader view, integrating MES with functions like quality, logistics, and maintenance, driving enterprise-wide optimization.
Think of MES as the tactical arm, handling immediate production needs, while MOM provides strategic oversight, leveraging MES data to streamline the entire manufacturing lifecycle. Together, they deliver a unified approach, balancing shop-floor precision with enterprise-level coordination to enhance efficiency, compliance, and overall performance.
The future of maintenance with virtual twins
Virtual twins take the concept of digital twins – which provide virtual models of physical assets and processes – to the next level by ensuring they are Model Based, dynamic, connected, reusable in multiple contexts, and by adding a 4th dimension – time. Dassault Systèmes has integrated virtual twin technology with its DELMIA MOM solution, enabling real-time feedback between the virtual and real worlds and allowing manufacturers to visualize, predict, and optimize their operations in unparalleled ways.
Key benefits of virtual twins:
- Real-Time Monitoring: Virtual twins provide a continuous, live view of equipment performance, ensuring that any anomalies or inefficiencies are immediately flagged.
- Predictive Analytics Integration: By coupling virtual twins with predictive maintenance algorithms, manufacturers can preempt equipment failures and schedule maintenance activities efficiently.
- Scenario Simulation: Manufacturers can run ‘what-if’ scenarios to understand the impact of operational adjustments, new production schedules, or unexpected demand surges.
- Sustainability Insights: Optimize energy use with the help of virtual twins to reduce material waste, and align operations with sustainability targets.
- Seamless Integration with MOM Systems: The DELMIA MOM platform integrates virtual twins directly into broader manufacturing workflows, creating a closed-loop system that continuously improves processes based on real-time data.
Navigating challenges in implementation
Despite the transformative potential of predictive maintenance, manufacturers often face hurdles when adopting IIoT-enabled solutions. Key challenges include:
- Data Overload and Management: IIoT generates massive amounts of data, often overwhelming traditional systems. The solution lies in edge computing, which processes data locally, reducing latency and ensuring real-time insights. Additionally, scalable data platforms such as DELMIA MOM aggregate and contextualize this data, turning it into actionable intelligence.
- Integration Complexities: Many manufacturers operate legacy systems that don’t easily integrate with modern IIoT technologies. Dassault Systèmes’ DELMIA MOM bridges this gap by creating a unified architecture that connects operational technology (OT) with IT systems, ensuring seamless data flow across the enterprise.
- Skills Shortages: The shift to predictive maintenance requires both IT and OT expertise, which many manufacturers lack. Cross-functional training programs and targeted recruitment efforts can help bridge this gap. Dassault Systèmes also supports this transition by providing intuitive tools and platforms that simplify adoption.
- Cybersecurity Risks: As IIoT expands, so do potential vulnerabilities. Manufacturers must implement robust security protocols, including encryption, regular audits, and compliance with industry standards to safeguard their systems.
Sustainability at the core of predictive maintenance
Predictive maintenance contributes to sustainability by reducing waste, optimizing resource use, and minimizing energy consumption. DELMIA MOM solutions integrate sustainability metrics into core operations, enabling manufacturers to track, measure, and improve their environmental performance.
Enhanced sustainability practices:
- Energy Optimization: Real-time monitoring and predictive insights reduce unnecessary energy usage by aligning production schedules with energy-efficient practices.
- Waste Reduction: Predictive algorithms identify inefficiencies, enabling manufacturers to reduce scrap and recycle materials effectively.
- Circular Economy Support: DELMIA MOM supports closed-loop systems, allowing manufacturers to reuse materials and minimize landfill contributions.
- Lifecycle Assessments: Simulate environmental impacts with virtual twins across a product’s lifecycle, enabling manufacturers to make informed decisions about design and production.
- Real-World Impact: For example, manufacturers using DELMIA MOM have reported up to a 25% reduction in their environmental footprint by leveraging IIoT for sustainability initiatives. These savings stem not only from operational efficiencies but also from smarter logistics and material sourcing strategies.
A vision for the future
Predictive maintenance and virtual twins are no longer future aspirations. They are necessities for manufacturers who want to stay competitive. DELMIA’s Manufacturing and Operations solutions exemplify how these technologies can be harnessed to drive efficiency, resilience, and sustainability. By embracing these innovations, manufacturers can ensure their operations are not only prepared for today’s challenges but also poised to lead in the smart factory revolution.
Bottom line: the factory of the future is not a concept; it’s a reality taking shape today. With tools like predictive maintenance and virtual twins, the possibilities are limitless.
Louis Columbus is currently serving as a member of the DELMIA Marketing team, where he assists with DELMIAWorks and robotics solutions. Previous positions include product management at Ingram Cloud, product marketing at iBASEt, Plex Systems, senior analyst at AMR Research (now Gartner), marketing and business development at Cincom Systems, Ingram Micro, a SaaS start-up and at hardware companies. Professional experience includes marketing, product management, sales and industry analyst roles in the enterprise software and IT industries. Columbus' academic background includes an MBA from Pepperdine University and completion of the Strategic Marketing Management and Digital Marketing Programs at the Stanford University Graduate School of Business. He teaches MBA courses in international business, global competitive strategies, international market research, and capstone courses in strategic planning and market research. Columbus has taught at California State University, Fullerton: University of California, Irvine; Marymount University, and Webster University.