Advanced Manufacturing

Predictive Maintenance for Automation

Preventive Maintenance Robot Automation IONA Preventive Maintenance Robot Automation IONA INSPHERE
Tuesday 5 October 2021, 11:49 AM

2 Minute Read

The Challenge

When a robot fails in production, unplanned downtime can cost over £10,000 per minute in high throughput systems. As mechanical systems, robots are also subject to wear and tear and their positional accurate can ‘drift’ over time. This can result in processes moving outside acceptable tolerance limits and, in some cases, having to scrap a part. Issues such as these can be caused by the robot itself but can also relate to the fixture or part varying in relation to the robot. The later in the process issues are ‘caught’, the higher the cost impact due to the additional value-added. Worst case the product goes to the customer with a fault which can cost millions in the case of product recalls.

How can IONA help?

With IONA installed, the position of the robot end-effector or TCP can be monitored in relation to the fixture or workpiece. By continually tracking movements over time, a pattern of behaviour can be established. If the process starts to ‘drift’ either due to a robot issue or the fixture, this will appear as varying from the normal behaviour and flag that an issue may occur. This insight can then be used to predict and then plan when actions need to be taken.

IONA System Outcomes

Gaining this forward-looking insight allows engineers to predict when maintenance is required. This allows it to be scheduled with minimal production disruption and also prevents maintenance operations from taking place when they are not necessary. This maximises the uptime of an automated production system and also reduces the costly risk of producing non-conforming parts.

Discover how IONA can help your business!

Download the Brochure to find out more about IONA and the ways we can help your business

Discover IONA System | Download the Brochure

Press Kit

To obtain a copy of our press kit, please message us using the adjacent contact form.


Thank you, we will be in contact shortly.

AMRC Sheffield
University of Wolves Racing
Mach Exhibition

Are you enjoying this article?

Sign up to our email newsletter and don't miss out on more articles like this.

* indicates required

Do you give consent for MTDMFG to send you communications?

You can unsubscribe at any time by clicking the link in the footer of our emails.