AI in Manufacturing: Maintenance 303

AI

Artificial intelligence. A computer program with algorithms that enable a machine or computer to imitate intelligent human behavior. AI allows machines to perform a process with autonomy.

air compressor

The power source of a pneumatic system that pressurizes ambient air. An air compressor directs pressurized air into the system in order to produce mechanical power.

Artificial intelligence

AI. A computer program with algorithms that enable a machine or computer to imitate intelligent human behavior. Artificial intelligence allows machines to perform a process with autonomy.

Automated welder

A machine or system that performs welding processes without human intervention. Automated welders may use robotics or computer numerical control (CNC).

Cycle time

The actual time it takes to perform a task and forward it to the next step. Cycle time may be adjusted by AI to reduce stress on equipment.

Dashboards

A data visualization tool that contains current and updated information related to performance and operations throughout the supply chain. Dashboards are used in smart factories to fully utilize data.

distributed control systems

DCSs. A control system consisting of programmable logic controllers placed strategically throughout a manufacturing facility. Distributed control systems require a high-speed communication network.

drift

The actual change in a measurement value when the same characteristic is measured by the same operator under the same conditions at different points in time. Drift indicates how often a measurement needs recalibration.

Electrical panel

A grouping of electrical devices that divide upstream electricity into separate circuits to reach individual components downstream. Electrical panels consist of fuses, circuit breakers, and other devices.

Escalation

The act of formally passing an alert to maintenance, engineering, or leadership when it exceeds defined limits or operator authority. Escalation can help identify high‑risk conditions and provide context, evidence, and priority so the issue can be addressed efficiently.

False negatives

A result that incorrectly indicates that a condition, event, or characteristic is absent when it is actually present. False negatives occur when a test or system fails to detect something that exists.

False positives

A result that incorrectly indicates the presence of a condition, event, or characteristic when it is actually not present. False positives occur where a test or model mistakenly labels something as positive.

Historical Data

Digital information that has been collected and stored over time. Historical data includes various data types and can be used to train digital optimization models.

Industrial Internet of Things

IIoT. A network of physical devices used in manufacturing containing embedded computing systems that allow them to send and receive data. The Industrial Internet of Things allows devices to exchange data and automate processes without any human intervention.

mechanical stress

A mechanical force that attempts to deform an object. Mechanical stress in excess may cause a part to break.

PdM

Predictive Maintenance. A maintenance approach that involves collecting data in order to anticipate and correct potential issues before they arise. PdM involves performing maintenance before failures occur to prevent unscheduled downtime and reduce the labor, cost, and time needed for repairs.

PM

Preventative maintenance. A maintenance approach where staff maintains equipment on a schedule, while it is in working order, to keep it from breaking down. PM may include lubricating, tightening, and replacing worn parts.

Pounds per square inch

psi. A common unit of pressure measurement. Pounds per square inch is derived from the English system.

Predictive maintenance

PdM. A maintenance approach that involves collecting data in order to anticipate and correct potential issues before they arise. Predictive maintenance involves performing maintenance before failures occur to prevent unscheduled downtime and reduce the labor, cost, and time needed for repairs.

Preventative maintenance

PM. A maintenance approach where staff maintains equipment on a schedule, while it is in working order, to keep it from breaking down. Preventive maintenance may include lubricating, tightening, and replacing worn parts.

Programmable logic controllers

PLC. A processor-driven device that uses logic-based software to provide electrical control to a machine or process. Programmable logic controllers can replace many physical relays and hard-wired connections in a process.

Reactive maintenance

RM. A maintenance approach where staff makes repairs in response to product and equipment failure. Reactive maintenance often has unintended consequences such as unexpected downtime, higher part costs, shorter product lifespan, and overall greater service costs.

real time

The actual time during which a process or event occurs. Real-time systems input and process data within milliseconds so that it is available virtually immediately as feedback.

Remaining Useful Life

RUL. An estimate of how long a machine or component can continue to operate safely and effectively before it fails or requires maintenance. Remaining useful life is calculated using condition data, historical trends, and operating context.

root cause analysis

RCA. A study to determine the first or underlying cause of a problem. Root cause analysis involves the collection and study of data to determine the true cause of a problem.

Sensors

A device that detects a change in a physical condition and turns it into an electrical signal. Sensors are common analog input devices that respond to variable conditions, such as pressure, temperature, or flow.

Smart manufacturing

A method of manufacturing designed to improve product design and processes through the integration of digital technology throughout the supply chain. Smart manufacturing increases connectivity across all areas of product development.

Supervisory control and data acquisition

SCADA. A variety of system types but, most often, an industrial system used to monitor and control a large process. Supervisory control and data acquisition controls can include one or more entire facilities.

Threshold

A limit at which a given parameter is no longer within tolerance. Thresholds identify readings as acceptable or unacceptable.

Tolerance band

An acceptable range of variation around a target value within which a system can operate without negatively affecting performance or quality. Tolerance band adjustments can be handled automatically without requiring alerts or intervention.