Resolving the Predictive Maintenance Conundrum

Condition monitoring utilizes trend analysis to predictively determine developing issues by monitoring the movement of machine modules, and allows intervention during planned downtime, rather than waiting for a catastrophic failure. Image courtesy of Cama North America.

Condition monitoring prevents unplanned downtime.

By Billy Goodman, Managing Director of Cama North America

Since 1981, we have been an international leader in the engineering and production of high technology secondary packaging systems. We offer complete integrated packaging lines – from primary packages to final packaging ready for palletizing, including cartoning, case packing, sleeving and robotics integration – serving the food (bakery, confectionery, coffee, ice cream, dairy, ready meals, grocery), non-food (personal, health and home care) and pet food industries.

From the first day we opened our plant, we have been trying to resolve the age-old dilemma of how to predictively maintain a machine. For most of our history and our industry’s history, the common practice to maintenance has been to touch a motor to see if it is too hot, look at the production floor for metal shavings or wait until the machine breaks down to fix whatever broke. Unfortunately, the historical methods resulted in unplanned downtime for machinery, often leading to long intervals of line activity trying to first diagnose the issue followed by finding the solution and parts to fix the problem.

Remote monitoring of the process and environmental sensors can be accomplished on the machine HMI or remotely. Image courtesy of Cama North America.

Sensory Monitors

Finally, a few years ago, we jumped on the Industry 4.0 bandwagon, determined to resolve the predictive maintenance conundrum. With the help our component suppliers, our technical engineering team investigated the available sensors compatible with our machinery. We termed our platform as “condition monitoring,” meaning by monitoring the movement of the machine modules, we could utilize trend analysis to predictively determine developing issues. We divided these sensory monitors into two categories: process sensors and environment sensors.

Environmental sensors are utilized to monitor moving parts and the machine framework, and process sensors are utilized to detect abnormalities in air flow, including compressed air and air generated by generators to produce vacuum. Image courtesy of Cama North America.

Process sensors are utilized to detect abnormalities in air flow, including compressed air and air generated by generators to produce vacuum. These sensors include air pressure and flow meters monitoring compressed air into and within the machinery; vacuum sensors to ensure any device is engaging with what it is picking (i.e., robotic end effector picking and placing products or a vacuum arm grabbing a case blank from a magazine) and leakage detection for any air escaping from hoses.

Environmental sensors are utilized for moving parts and the machine framework, diagnosing any changes from the “normal” trend. Temperature is a key sensor, detecting the heat generated by moving parts, including shafts and motors. Vibration is another sensor that indicates the stability of modules or the machine during operation. If the temperature or vibratory trend increases during the machinery operation, it indicates that maintenance is necessary to avoid downtime. This trend analysis allows intervention to the machine to solve an issue typically during planned downtime, rather than waiting for a catastrophic failure.

Condition monitoring has provided us with the basis to conduct predictive maintenance during normal machine operation without having to intervene production. Remote monitoring of the process and environmental sensors can be accomplished on the machine HMI or remotely.

Since 1981, Cama has been an international leader in the engineering and production of high technology secondary packaging systems. Image courtesy of Cama North America.

About the Author

Billy Goodman is the Managing Director of Cama North America, serving leadership roles within the packaging industry for over 30 years. Since 1981, Cama Group has been an international leader in the engineering and production of high technology secondary packaging systems. Learn more at: https://camagroup.com/