Fault Detection
Optimising Equipment Fault Detection with RPA Automation
Key Solution: Robotic Process Automation (RPA)
Challenge
Manual Data Handling Issues: Employees manually copy sensor data, which can lead to errors and omissions, resulting in delayed fault detection.
Production Impact: Late discovery of equipment faults can severely disrupt production and incur significant costs.
Inefficient Monitoring: Manual monitoring cannot support continuous, round-the-clock analysis, limiting both the frequency and accuracy of fault detection.
Solutions
RPA automates the collection and analysis of sensor data from machinery, operating continuously 24/7. Once a fault is detected, the system immediately sends an email alert to the relevant personnel, freeing technical staff from repetitive tasks and enabling early intervention to minimise production disruption.
Before Implementation:
- Sensor data is manually copied, increasing the risk of errors and omissions.
- Limited to periodic manual checks, which may miss early signs of faults.
- Delayed fault detection can lead to extended equipment downtime and production delays.
- Technical staff spend significant time on monotonous, manual data processing tasks.
After Implementation:
- Automated data collection ensures consistent and error-free monitoring.
- Continuous 24/7 monitoring provides real-time fault detection.
- Immediate alerts enable swift corrective action, reducing downtime.
- Automation liberates technical personnel for more strategic, high-value work.
Impact
99% Accuracy
90% Efficiency
50% Reduced Operational Downtime