Development of a Modern Machinery Monitoring and Testing Application for Predictive Maintenance

The client requires a modern, user-friendly application to execute tests and continuously monitor the condition of their mining equipment, such as vibrating screens, to enhance maintenance practices. Current systems lack comprehensive features, real-time insights, and efficient testing modes, leading to delayed issue detection and increased maintenance costs.

A mid-sized manufacturing firm specializing in mining equipment production, aiming to improve machinery maintenance and monitoring.

• Refactor and redesign existing equipment testing and monitoring software to improve usability and functionality.
• Develop a comprehensive application with multiple testing modes, including impact and orbit testing, for equipment condition assessment.
• Enable real-time data collection and cloud-based report generation for ongoing equipment health analysis.
• Implement an intuitive user interface to facilitate easier operation and data interpretation.
• Reduce maintenance costs by enabling earlier detection of potential equipment issues, thereby decreasing unplanned downtime.
• Leverage system data and research capabilities to inform product improvements and future development efforts.

• Impact Mode: facilitating testing of equipment components from a rest state to assess exposure and damage.
• Orbit Mode: enabling operation-based testing to evaluate equipment performance during active use.
• Automated report generation with cloud storage integration for easy access and analysis.
• Intuitive, user-friendly interface design to streamline testing workflows.
• Application management system for configuration, user roles, and data security.
• Data collection and analytics module for ongoing research and product improvement.

• Cloud storage services for report management
• Machine data acquisition systems
• User authentication and access control systems

• System should support scalability to handle increasing data volumes from multiple machines
• Real-time monitoring capabilities with minimal latency
• High security standards to protect sensitive operational and machine data
• System reliability with 99.9% uptime and robust error handling
• User interface should be accessible via desktop and mobile devices for operational convenience

The implementation of this modernized monitoring and testing system is expected to reduce machine maintenance costs by approximately 23%, enable detection of maintenance issues three months earlier on average, and decrease unplanned downtime. Additionally, the system will support research initiatives, leading to continuous product improvements and enhanced operational efficiency.