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.

Solution

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

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