Internet of Things
PREDICTIVE MAINTENANCE USING IIoT DATA IN MANUFACTURING
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redictive maintenance and virtual twins are no longer future aspirations. They are necessities for manufacturers who want to stay competitive.
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 is 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; these dynamic digital replicas bridge the gap between the physical and virtual worlds, enabling manufacturers to simulate, optimise, 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 labour management, 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 labour and materials, collecting real-time data, and ensuring
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4th dimension – time. The best-in-class virtual twins are capable of integrating with MOM software, enabling real-time feedback between the virtual and real worlds and allowing manufacturers to visualise, predict, and optimise 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.
By Louis Columbus, senior industry marketing manager at DELMIA
production efficiency. MOM, however, takes a broader view, integrating MES with functions like quality, logistics, and maintenance, driving enterprise-wide optimisation.
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
Predictive Analytics Integration: By coupling virtual twins with predictive maintenance algorithms, manufacturers can pre-empt 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: Optimise energy use with the help of virtual twins to reduce material waste, and align operations with sustainability targets.
Seamless Integration with MOM Systems: Modern MOM platforms integrates withvirtual twins directly into broader manufacturing workflows, creating a closed- loop system that continuously improves processes based on real-time data.
November 2025 Instrumentation Monthly
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