Are smart tools giving electricians a leap in efficiency?
As we look ahead to the next decade, one thing is clear: the way electricians and plant technicians interact with machines is undergoing a fundamental shift. Smart tools in particular are transforming how we collect and use data on the plant floor. These tools are not just gadgets—they’re enablers of efficiency, safety, and long-term business success.
But the question remains: Are smart tools truly giving electricians the leap in efficiency they need? To answer that, we need to understand what makes these tools "smart," how they’re being used, and where this technology is taking us.
Defining smart tools: The next evolution in industrial maintenance
The term "smart tools" has become a buzzword in our industry, but it’s essential to clarify what it really means. Smart tools, in their simplest form, are devices that (1) collect data through sensors and (2) process that data to give technicians actionable insights.
Traditionally, tools have been task-specific and reactive; smart tools, on the other hand, are proactive and multifunctional. These tools don't just measure—they analyze and recommend. They’re evolving from basic task enablers to intelligent agents that provide real-time feedback to the technician. This feedback isn't just raw data, but actionable insights that improve decision-making and efficiency.
Smart tools are continuously evolving as being enabled by edge computing, cloud connectivity, and artificial intelligence (AI). A great example of this evolution is the move from basic electrical meters to multimeters with advanced diagnostics that can identify issues before they become critical. This leap allows electricians to anticipate problems, reducing downtime and the risk of catastrophic failure. As smart tools become more sophisticated, they will not only assist in diagnosing but will also predict future maintenance needs through AI-driven insights.
Addressing real-world challenges on the plant floor
One of the most significant benefits of smart tools is how they address challenges that conventional tools simply can't handle. The modern plant floor is complex, with machines that require different types of monitoring—voltage, temperature, pressure, and vibration, to name a few. Technicians often carry a variety of tools to meet these needs, but this approach is inefficient and can lead to errors in data interpretation.
Smart tools, with their ability to capture and process data in real-time, are becoming critical in ensuring that technicians can react immediately to any signs of trouble. Imagine a thermal imager that scans hundreds of drywall panels on the production line in minutes, identifying defects that could lead to expensive recalls or legal issues down the line. These tools aren’t just making technicians more efficient—they're protecting businesses from costly mistakes.
The Power of Predictive Maintenance. Beyond real-time diagnostics, smart tools are paving the way for predictive maintenance. Traditionally, maintenance has been reactive or scheduled, based on set intervals. But what if your equipment could tell you when it needs attention before it breaks down? That’s where smart tools come into play.
Take the example of vibration sensors installed on rotating machinery. These sensors, combined with AI, can predict when a machine is likely to fail based on patterns in the data. This kind of predictive maintenance allows technicians to schedule repairs before a breakdown occurs, dramatically reducing unplanned downtime (see Figure 1).
In the near future, we’ll see more tools that integrate predictive maintenance features. This is where AI and machine learning (ML) shine. By constantly analyzing data from various sources—whether it's a machine’s vibration, temperature, or electrical output—these smart tools can flag potential issues before they escalate. The result? Technicians spend less time troubleshooting and more time preventing failures, leading to improved uptime and reliability.
Efficiency and safety: A powerful combination. Another area where smart tools are making a huge impact is safety. Working in industrial environments comes with inherent risks, especially when dealing with electrical systems, high-pressure equipment, or hazardous environments. Smart tools are helping mitigate these risks by enabling more hands-off maintenance (see Figure 2).
For example, with connected smart tools, technicians can monitor equipment remotely, reducing the need for physical inspections in hazardous areas. When issues do arise, technicians can receive notifications on their smartphones or tablets, allowing them to address problems quickly and safely.
Additionally, the use of predictive maintenance reduces the frequency of manual inspections, lowering the exposure of technicians to potentially hazardous situations. By diagnosing and even fixing problems remotely, smart tools minimize unnecessary risks, keeping plant maintenance personnel safer.
The changing role of the plant maintenance technician
Looking ahead, smart tools will fundamentally change the role of plant maintenance technicians. As these tools become more sophisticated, technicians will shift from being reactive troubleshooters to proactive problem-solvers. Their role will evolve to include more strategic decision-making, backed by real-time data and AI-driven insights.
One of the most exciting developments is the potential for augmented reality (AR) in maintenance work. Imagine a technician wearing AR glasses that display equipment data right in front of their eyes, while their hands are free to work. In this scenario, a smart tool could provide step-by-step instructions or even communicate with a central database to offer guidance on industry standards or troubleshooting techniques. It’s a future that’s not as far off as you might think.
Overcoming barriers to adoption. Of course, every new technology faces adoption challenges. Technicians and plant managers may be hesitant to adopt smart tools, worrying about the learning curve or cost of implementation. But the key to overcoming these barriers is simple: smart tools must make life easier, cost effective, and safer, not more complicated. The adoption of smart tools must reduce the number of steps required to complete a task, and it should offer a clear return on investment by lowering downtime, improving accuracy, and enhancing safety. But beyond the immediate benefits, it’s essential for companies to invest in training and education to help technicians fully leverage these new technologies. The more intuitive and user-friendly the tools, the quicker they will be adopted.
Sustainability and efficiency. Smart tools are also contributing to broader goals, such as sustainability and energy efficiency. For industries focused on environmental responsibility—whether it’s renewable energy or reducing carbon footprints—smart tools provide data-driven insights that help optimize operations. On a more practical level, smart tools themselves are being designed with sustainability in mind. By reducing waste and inefficiency on the plant floor, these tools play a direct role in lowering energy consumption and minimizing environmental impact.
AI and the future of smart tools
Artificial intelligence is going to be the driving force behind the next generation of smart tools. As AI becomes more advanced, it will increasingly serve as a co-pilot for technicians, augmenting human decision-making. AI can process massive amounts of data quickly, identifying patterns and trends that would be impossible for a human to decipher in short intervals of time. By integrating AI into smart tools, we create a partnership where human intuition and machine intelligence work together.
Looking ahead, the possibilities are endless. As smart tools become more intelligent and connected, the role of the technician will continue to evolve. What’s certain is that these tools are not just a leap in efficiency—they’re a leap in the way we think about plant maintenance and the role of technicians in the future of industrial operations.
In conclusion, smart tools are not just a passing trend—they are evolving as a transformative force in industrial maintenance. They offer electricians and technicians a significant leap in efficiency, safety, and capability. The future of plant maintenance is here, and it’s smarter than ever.