From Preventative to Predictive Maintenance of Automation
The transition from preventive to predictive maintenance and the advantages it
can offer to warehouse automation systems
By Nate Aswege, Director of Marketing North America, Addverb Technologies
Any industrial business has always needed maintenance to ensure that machines and
equipment run effectively and dependably, lowering the likelihood of unplanned malfunctions
and downtime. With regularly scheduled maintenance operations carried out to keep equipment
in excellent working order, maintenance has traditionally been carried out on a preventative
Let's look at the transition from preventive to predictive maintenance and the advantages it can
offer to warehouse automation systems.
A crucial step in guaranteeing the durability and effective operation of automated systems is
preventive maintenance. When establishing their maintenance programs, businesses should be
aware of the disadvantages that it brings.
Preventive maintenance has a number of disadvantages, including a high price tag. It can be
costly, especially for intricate automated systems with numerous parts. Preventive maintenance
can be expensive for businesses, especially small and medium-sized ones with limited
resources because of the high costs of components, labor, and specialized equipment required
to complete it.
Companies may find it difficult to allocate resources for preventative maintenance, especially
those with tight budgets. Preventive maintenance necessitates devoted resources, such as
qualified workers and unique tools. Businesses must make sure they have the tools at their
disposal to do maintenance efficiently. Preventive maintenance requires trained people. In order
to carry out maintenance jobs effectively and securely, they must be educated about the
automated systems that are being installed. However, it can be difficult to find and keep talented
workers, especially in fields where specialized talents are in great demand. Preventive
maintenance also needs specialized equipment. Because automated systems are frequently
complicated, maintenance calls for specialized tools and equipment to identify and resolve
The possibility of false positives is another potential downside of preventative maintenance.
Maintenance workers may detect a problem that doesn't actually exist throughout the inspection
process. These erroneous positive results may need expensive and time-consuming
unnecessary component repairs or replacements. To reduce the danger of false positives,
businesses must guarantee that maintenance employees are properly trained and use the right
Predictive maintenance is a more advanced approach to maintenance that predicts when a
repair is necessary using data analytics and machine learning algorithms. Predictive
maintenance involves tracking the functioning of machinery in real time, gathering information
on variables like temperature, vibration, and power usage, and then using that information to
spot patterns and anomalies that could point to possible defects or breakdowns.
For warehouse automation systems, predictive maintenance offers major advantages.
Manufacturing processes frequently depend on warehousing robotics equipment, such as
conveyors, and any downtime can significantly affect its productivity and profitability. By
foreseeing when maintenance is necessary and allowing for the scheduling of maintenance
work, predictive maintenance can help to reduce the risk of downtime.
Improved efficiency is one of the main advantages of predictive maintenance. Downtime can be
reduced and productivity can be increased by only scheduling maintenance when it is
necessary. Predictive maintenance involves chances for optimization, including changing
operating parameters to boost efficiency or use less energy. Businesses can gradually increase
their productivity and cut costs by making tiny modifications based on data analysis.
Additionally, predictive maintenance may increase security. Businesses can take steps to stop
accidents and injuries by seeing possible problems before they become safety hazards.
Businesses can also spot possible safety hazards, like excessive vibration or temperature, by
monitoring equipment performance in real-time and acting to remedy them before they cause
Additionally, predictive maintenance might assist companies in cost-cutting. Businesses can
save money by seeing potential problems before they become expensive breakdowns and
repairs. Predictive maintenance can also assist organizations to increase the equipment's
lifespan and avoid expensive replacements. Predictive maintenance can optimize equipment
performance while lowering energy use and other operational expenses, resulting in substantial
long-term cost savings.
In conclusion, organizations will drastically benefit from the switch from preventive to predictive
maintenance of warehouse automation. Traditional maintenance techniques frequently only
address issues after they arise and are reactive. Reactive maintenance has its shortcomings,
but preventative maintenance has improved upon it. Contrarily, predictive maintenance makes
use of data and analytics to spot possible problems before they arise, enabling maintenance to
be scheduled at the most advantageous moment, minimizing downtime, and boosting
productivity. Businesses may increase productivity, increase safety, and cut costs by introducing
predictive maintenance, which will have a big impact over time. Although implementing
predictive maintenance has its hurdles, the advantages are obvious, and companies that adopt
this strategy will be better positioned to succeed in the new era of automation.
Addverb provides smart end-to-end warehouse and industrial automation and intralogistics
solutions. Addverb's fleet of automated robots, material handling technologies, and software
solutions comprising an extensive portfolio of fixed and flexible automation solutions help
improve the performance and accuracy of warehouse and factory operations. Addverb's mission
is to discover a customer's warehousing problem, design an appropriate customized automation
solution to the identified problem, deliver the solution, and provide dedicated after-sales support.
Addverb's headquarters, manufacturing, and R&D facilities are in India, with global offices in
Australia, Singapore, the Netherlands, the USA, Germany, and the UAE. Addverb's current
100+ customers include Coca Cola, PepsiCo, DHL, Amazon, Colgate Palmolive, Reliance,
Unilever, Flipkart, Johnson & Johnson, and PAR Pharmaceutical. For more information visit