South Carolina Manufacturers Tackle Downtime with Data-Driven Maintenance

Greenville, SC – At the 2024 South Carolina Manufacturers Conference & Expo, the buzz wasn’t just about the latest machinery; it was about the intelligent systems keeping those machines running. As manufacturers grapple with rising costs, labor shortages, and the ever-present threat of downtime, companies like Hexagon and DigitalThinker are offering data-driven solutions to optimize asset management.

“Downtime means cost,” Jeremy Hicks, VP of Validated Manufacturing for Hexagon, emphasized. “And in industries like pharmaceuticals or oil and gas, that cost can be astronomical.”

The challenge? Transitioning from outdated paper-based systems or basic spreadsheets to sophisticated Enterprise Asset Management (EAM) solutions. Alex Boland, President at DigitalThinker, explained, “EAM is your central repository of data. It eliminates tribal knowledge stuck in notebooks and empowers teams with real-time insights.”

Watch the Video HERE.

 

From Reactive to Predictive Maintenance

The traditional approach to maintenance has been largely reactive – fixing equipment after it breaks. However, the rise of IoT and machine learning is enabling a shift towards predictive and prescriptive maintenance.

“We’re helping manufacturers make sense of their data across the entire asset lifecycle,” Hicks said. “This allows them to make smart decisions, optimize production, and minimize downtime.”

Boland illustrated this with a real-world example: “We’re implementing Hexagon EAM for a lumber manufacturer, using IoT sensors on band saws to track the number of cuts. When a saw reaches a critical threshold, the system automatically generates a maintenance work order.”

This level of automation not only reduces downtime but also addresses the growing skills gap in maintenance. “With digital applications, technicians can access checklists and standard operating procedures on tablets, eliminating the need to run back and forth for information,” Boland explained.

 

Empowering the Workforce and Building Resilience

Beyond efficiency gains, these solutions are also improving employee morale. “When maintenance teams have the tools they need, they’re more engaged and less stressed,” Boland noted. “It’s about empowering them to do their best work.”

Moreover, the emphasis on data and digital twins is enabling manufacturers to build resilience. “Establishing redundancies and ensuring continuity when experienced technicians retire is crucial,” Hicks said. “Data-driven systems help capture and transfer that knowledge.”

 

The Importance of Partnership and Ongoing Training

Implementing EAM is not just about installing software; it’s about building a long-term partnership. “We focus on understanding our clients’ business processes and providing ongoing training and support,” Boland said. “Our DTI Academy offers free resources and live sessions to ensure users are maximizing the system’s potential.”

Digital Thinker emphasizes a “Envision, Act, Master” approach, guiding clients from initial planning to continuous improvement. “Asset management should be a strategic priority from day one,” Boland stressed.

 

Looking Ahead: AI and Reliability-Centered Maintenance

The future of manufacturing maintenance is being shaped by emerging trends like AI and reliability-centered maintenance (RCM). “AI is here, and it’s going to revolutionize how we interact with our assets,” Hicks predicted. “The quality of data will be critical in leveraging AI for predictive maintenance.”

Boland highlighted the resurgence of RCM, a strategy focused on understanding why assets fail and preventing future failures. “We’re seeing a shift towards more data-driven decision-making, allowing manufacturers to optimize maintenance spending and minimize risk,” he said.

As South Carolina’s manufacturing sector continues to evolve, the adoption of intelligent asset management solutions will be essential for staying competitive. Companies like Hexagon and Digital Thinker are at the forefront, empowering manufacturers to embrace data-driven strategies and build a more resilient future.

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