INDUSTRY 4.0 / SMART FACTORIES
2024, the largest share. Five years prior, it was at 8 per cent. This massive jump is primarily due to widespread digitalisation. Connecting machinery to a network creates new vulnerabilities. Smart factories must implement access controls and automate security.
FOCUSING ON THE HUMAN ELEMENT TO EXPEDITE ACCEPTANCE Leaders cannot guarantee the technical side of things will be a success without considering the human element. Many workers have extensive of existing systems very well. As a result, plants sometimes get by without proactive condition monitoring. However, times are changing, and skillsets
are becoming outdated. Still, workers may be reluctant to embrace the change in the status quo. To increase their acceptance of new technologies, management must clearly emphasising that it will save the team time and eliminate human error. After generating enthusiasm, training can begin. Staggered implementation can decrease friction because the workload is lighter. A trial- Fostering a data-driven culture during training can improve the acceptance rate and accelerate progress. On an organisational level, upkeep is often
seen as a necessary process that must be completed cost-effectively, rather than a strategic component of a facility’s broader success. As a result, higher-ups often only approve investments if the payback period is relatively short. Yet, the positive effects of predictive maintenance can only be accurately measured in the medium and long term.
VARIATIONS IN SUCCESS AMONG EARLY ADOPTERS technology is relatively affordable, making implementation strategically sound, especially for smart factories that possess a wealth of information. However, the rate of success varies depending on project scope and facility size, among other factors. The top 50 per cent of organisations using
predictive maintenance spend 212.3 per cent more on direct maintenance expenses than the bottom 50 per cent. The top organisations experienced nearly 20 per cent per cent fewer incidents of unplanned downtime and 87.3 per cent fewer defects due to maintenance issues. However, they spent more on additional maintenance due to faults and had a greater volume of sales lost due to delays. This study demonstrates that leaders
cannot throw money at the problem and expect solely positive results. Moreover, no single plan guarantees success, as every production
line is unique. Even facilities within the same organisation may need to approach upkeep differently. Implementation requires extensive planning.
exists, there are best practices manufacturing professionals can follow to accelerate their efforts and improve the outcomes. Their primary focus should be on the technical aspects, as well as cybersecurity and the human element.
THE FUTURE OF SMART FACTORIES For smart factories, implementing predictive maintenance is a complex journey that involves careful solution selection, intensive technician training and team-wide empowerment. Ensuring the new approach aligns with existing systems is key, so leaders must prioritise hardware compatibility and broader interoperability. If the program is successful, it will transform
into a value-adding area for the factory. No one- so professionals must develop their own. A staggered integration approach that begins with a small-scale pilot project can help them test their method before rolling it out facility-wide. Initially, not all equipment needs to be part of
the program. Technicians can focus on one or two critical assets for a few weeks to test their value to stakeholders.
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FACTORY&HANDLINGSOLUTIONS | OCTOBER 2025 17
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