CONDITION MONITORING M


WHY MOTION SYSTEM RELIABILITY IS CRITICAL FOR LIGHTS-OUT PRODUCTION


PREDICTIVE MAINTENANCE IN MANUFACTURING:


anufacturers today are under intense pressure to increase productivity while managing rising operational costs and persistent labour shortages. Automation and robotics are increasingly seen as the solution, enabling facilities to operate continuously with minimal human intervention. However, the shift toward automated production also increases the consequences of equipment failure. Research across the manufacturing sector suggests that downtime can cost organisations up to £1.36 million per hour in some industries, highlighting just how expensive unexpected interruptions can be. When production lines operate continuously, even a brief mechanical failure can disrupt supply chains, delay deliveries and reduce overall operational efficiency. For companies investing heavily in automation technologies, maintaining uptime is essential to protecting both productivity and return on investment.


PREDICTIVE MAINTENANCE IN MANUFACTURING To address these risks, many organisations are adopting predictive maintenance strategies. Unlike reactive maintenance, which addresses failures after they occur, predictive maintenance uses data and monitoring technologies to identify potential problems before they lead to downtime. By monitoring equipment performance through sensors and condition monitoring tools, engineers can detect subtle changes that indicate wear or malfunction. This allows maintenance teams to intervene before a component fails, helping organisations avoid costly production stoppages.


KEY BENEFITS OF PREDICTIVE MAINTENANCE INCLUDE:


Reduced unplanned downtime Lower long-term maintenance costs Extended equipment lifespan Improved production reliability


More efficient use of maintenance resources


As manufacturers push towards fully autonomous operations, predictive maintenance is becoming an essential part of industrial reliability strategies.


MOTION CONTROL SYSTEMS: THE BACKBONE OF AUTOMATED PRODUCTION


While predictive maintenance often focuses on


Fully autonomous production environments promise efficiency gains and lower overheads — but they also leave no room for unexpected downtime. In facilities designed to run with minimal human intervention, even a minor motor failure can halt output and undermine return on investment. Here, Dave Walsha, sales and marketing


director at DC motor supplier Electro Mechanical Systems (EMS), explores why the success of lights-out manufacturing depends not only on advanced robotics and control software, but on the motion components at the heart of automated systems.


software analytics and monitoring platforms, the physical reliability of machine components remains equally important.


At the centre of most automated manufacturing systems are motion control components such as motors, actuators and drive systems. These components enable robotic movement, conveyor operation, precision assembly and many other automated processes.


In lights-out manufacturing environments, these systems may operate continuously for extended periods with little or no human supervision. As a result, motion components must be capable of handling:


Continuous duty cycles Frequent start-stop operations Variable loads and operating speeds Harsh industrial environments


If a critical motion component fails, the entire automated process can grind to a halt.


DESIGNING MOTION SYSTEMS FOR LONGEVITY AND RELIABILITY


For predictive maintenance to work effectively, motion control systems must be designed with durability and reliability in mind from the outset. High-quality motors and drive systems offer consistent performance over long operational lifetimes, making it easier for monitoring systems to detect genuine anomalies before failures occur.


30 SPRING/SUMMER 2026 | INDUSTRIAL COMPLIANCE


KEY FACTORS THAT INFLUENCE MOTION SYSTEM RELIABILITY INCLUDE:


Robust engineering design


Components built for demanding industrial environments can withstand heavy workloads and prolonged operation.


Stable performance characteristics Consistent torque, speed and thermal behaviour enable predictive maintenance systems to accurately identify abnormal conditions.


Integration with monitoring technologies Modern motion components that work seamlessly with sensors and condition monitoring systems support more effective predictive maintenance strategies.


By prioritising these factors during the design stage, manufacturers can significantly reduce the likelihood of unexpected machine failures.


AUTOMATION IS INCREASING THE PRESSURE ON MAINTENANCE STRATEGIES


Several industry trends are accelerating the adoption of predictive maintenance. Manufacturers are dealing with ongoing labour shortages, making it more difficult to rely on traditional inspection-based maintenance routines. At the same time, rising energy and operational costs are forcing organisations to maximise production efficiency and minimise downtime. Automation and lights-out manufacturing offer


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