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Digital Logsheet as a Real-time Monitoring Tool in Industrial Maintenance

by Sinthia Dwi Yolandasari for Education September 2, 2024 0 COMMENTS

In the current digital era, technological transformation has brought significant changes across various industrial sectors, including the field of maintenance. One of the popular innovations is the use of digital logsheets as a real-time monitoring tool. Digital logsheets not only replace the often slow and error-prone manual systems but also offer more accurate and efficient monitoring capabilities. This article will delve into the benefits, operation, and implementation of digital logsheets as a real-time monitoring tool in industrial maintenance.

What is a Digital Logsheets?

A digital logsheets is an electronic form of traditional worksheets used to record operational, maintenance, and inspection data in industries. Unlike manual logsheets that use paper, digital logsheets utilize software to enable automatic and integrated data recording, storage, and analysis. Data collected through digital logsheets can be accessed in real-time by technicians and managers, facilitating quick and accurate decision-making.

Benefits of Using Digital Logsheets in Industrial Maintenance

Real-time Monitoring

One of the main advantages of digital logsheets is their ability to provide real-time maintenance data. This allows technicians to quickly detect emerging issues and take preventive actions before more significant damage occurs. With real-time monitoring, machine downtime can be significantly reduced, ultimately improving productivity and operational efficiency.

Reducing Human Error

Manual logsheets are often prone to human errors, such as inaccurate data recording or loss of important information. Digital logsheets automatically record data through the system, minimizing the risk of human error. Additionally, data validation features on digital logsheets ensure that recorded information meets established standards.

Ease of Access and Data Analysis

Data recorded through digital logsheets can be easily accessed by various stakeholders, both on-site and off-site. This enables more in-depth data analysis, such as damage trends, maintenance effectiveness, and spare parts needs. Consequently, management can make better decisions based on accurate and up-to-date data.

Time and Cost Efficiency

Using digital logsheets can save time and costs typically spent on managing manual logsheets. Manual data recording, storage, and processing require considerable time and labor. With digital logsheets, all these processes can be automated, allowing companies to allocate resources to more strategic areas.

How Digital Logsheets Work in Industrial Maintenance

Automatic Data Recording

Digital logsheets are equipped with sensors and IoT (Internet of Things) devices that can automatically collect operational data from machines and equipment. This data is then sent to a central server for storage and analysis. In industrial maintenance, recorded data typically includes temperature, pressure, rotation speed, and other performance indicators.

Integration with Maintenance Management Systems

Digital logsheets are often integrated with maintenance management systems (CMMS – Computerized Maintenance Management System), allowing for more efficient asset management and maintenance scheduling. Data collected through digital logsheets can be directly used for planning preventive maintenance, managing spare parts inventory, and optimizing human resources.

Use of Cloud Technology

Many digital logsheets use cloud technology for data storage, enabling access from anywhere and at any time. Cloud technology also ensures that stored data is secure and recoverable in case of disasters or system failures. With cloud storage, companies can also reduce the IT infrastructure costs typically required for local data storage and management.

Predictive Analysis

Digital logsheets can also be used for predictive analysis, a method that uses historical data and algorithms to predict future machine failures. With predictive analysis, technicians can perform maintenance before damage occurs, reducing the risk of unexpected downtime.

Implementation of Digital Logsheets in Industrial Maintenance

Preparation and Planning

Before implementing digital logsheets, companies need to undertake thorough planning. This includes selecting appropriate software, adjusting operational processes, and training technicians. Additionally, it is crucial to ensure that all hardware, such as sensors and IoT devices, is correctly installed and functioning as required.

Training and Socialization

Training is a vital part of digital logsheets implementation. Technicians and maintenance staff need to understand how to use the related software and hardware, as well as how to interpret the collected data. Socialization is also important to ensure that all stakeholders understand the benefits and objectives of using digital logsheets.

Testing and Evaluation

Before fully adopting digital logsheets, companies should conduct a pilot test on specific parts of their operations. This test will help identify potential issues and areas for improvement. Once the pilot test is successful, companies can proceed with full implementation and continue evaluating the system to ensure optimal performance.

Integration with Other Systems

Integrating digital logsheets with other systems, such as ERP (Enterprise Resource Planning) and CMMS, is crucial for creating an integrated maintenance ecosystem. This integration allows data collected by digital logsheets to be maximally utilized to support various operational aspects of the company, from asset management to human resource management.

Challenges in Implementing Digital Logsheets

High Initial Costs

One of the main challenges in implementing digital logsheets is the high initial costs, particularly for small and medium-sized companies. These costs include purchasing hardware, software licenses, as well as installation and training expenses. However, these costs are usually justified by the long-term benefits gained.

Infrastructure Limitations

In some industries, infrastructure limitations, such as unstable internet connections or lack of technical support, can be obstacles to implementing digital logsheets. Therefore, companies need to ensure they have adequate infrastructure before starting the implementation process.

Resistance to Change

As with other technological changes, the implementation of digital logsheets may face resistance from employees accustomed to manual systems. Management needs to provide understanding about the benefits of digital logsheets and how this technology can ease their work.

Data Security

Data security is a critical issue in using digital logsheets, especially since data is stored and accessed over the internet. Companies must ensure that the systems used have adequate security features, such as data encryption and user authentication, to protect sensitive information from cyber threats.

Case Studies: Successful Implementation of Digital Logsheets

Large Manufacturing Company

A large manufacturing company in Indonesia successfully reduced machine downtime by 30% after implementing digital logsheets in their maintenance process. By using digital logsheets, the company could monitor machine conditions in real-time and perform preventive maintenance more effectively.

Food Processing Plant

A food processing plant implemented digital logsheets to monitor temperature and humidity in their production facility. Real-time monitoring allowed the company to ensure that the products produced met stringent quality and safety standards.

Oil and Gas Industry

In the oil and gas sector, a company used digital logsheets to monitor pressure and flow in their distribution pipelines. The real-time data obtained allowed the company to detect leaks early and prevent potential significant losses.

Conclusion

Digital logsheets represent an innovation that brings many benefits to industrial maintenance, particularly in real-time monitoring. With the ability to automatically record and analyze data, digital logsheets help companies reduce downtime, increase efficiency, and optimize resource use. Although there are some challenges in implementation, the long-term benefits offered by digital logsheets make it a valuable investment for today’s industries. Companies that successfully adopt this technology will be at the forefront of facing challenges and opportunities in the era of industry 4.0.