Any organization that relies on heavy and complex devices or machinery knows that frequent maintenance is important to keep them running and functioning efficiently.
If you are in the manufacturing business, you are aware that without regular maintenance, the machinery can break down, which eventually leads to costly repairs and replacements as well as downtimes.
Preventative maintenance is a common practice that entails regular inspection and tuning of equipment, whether they require it or not. However, there’s an emerging practice that aims to make maintenance of machinery more cost-effective and efficient.
Predictive maintenance is generally the practice of maintaining your machines and devices before they break down.
Some machines might run better than others, which means that organizations can save on maintenance and downtime costs if they know when to tune machines up, instead of keeping a tune-up and maintenance schedule.
How Predictive Maintenance Works
In general, predictive maintenance relies mostly on the internet of things sensors (IoT) that are wirelessly connected to consoles that collect and analyze data from your machines.
These sensors can detect a wide range of data, feed it to a computer and then present it in a manageable form for you.
From temperature to ultrasonic and vibrations detection, the data received from the IoT sensors can easily tell you a lot about how a certain machine is running.
Thermic sensors can determine if there’s too much friction on particular moving parts. Vibration sensors usually detect any subtle and unusual changes. The other sensors monitor lubricant and oil levels to ensure that it’s clean, and there is enough of it.
Machine learning normally breaks down all the data and keys it in the setting of machine wear and performance. According to Andromeda, the IoT programs will alert you if a machine breakdown is imminent or when maintenance is required using the huge amounts of data collected.
Benefits Of Predictive Maintenance
1. It Increases Production
The availability and convenience of process systems normally go up after the implementation of a predictive maintenance program.
This improvement can be as great as 30%. The increase is strictly based on the availability of machines and doesn’t include improved process returns.
Nonetheless, a complete predictive maintenance program that includes monitoring of process parameters can also boost the operating efficiency, leading to the productivity of processing and manufacturing plants.
2. It Improves The Safety Of Your Employees
Early warnings and detection of machine problems normally reduce the risks of destructive failures that can lead to death or personal injury.
This incredible benefit is supported by numerous insurance firms, which have given benefit reductions for companies that have adopted a condition-based predictive program.
3. It Supports Verification Of Machine Repairs
If your existing machines were undergoing repairs, you could use vibration analysis to determine whether the repairs have corrected all the identified issues or led to more abnormal behavior before starting the system again.
That eliminates any need for another shutdown, which is usually necessary to correct incomplete or inadequate repairs. The data obtained in predictive maintenance programs can be utilized in scheduling plant shutdowns.
Most factories try to schedule their preventive maintenance servicing and fix major problems during their annual maintenance shutdowns.
The predictive data given by the program can provide the information you need to plan for certain repairs and other tasks during the shutdown, as well.
4. It Increases The Service Life Of Machinery And Equipment Parts
The prevention of failures and early detection of equipment problems will enhance the service life of all your machines. You’ll note the increase in the lifespan after adopting a good predictive maintenance program within a certain period.
Predictive maintenance programs usually prevent serious damages to your machines, and this significantly reduces the gravity of damages hence increasing your asset’s service life.
One of the major benefits of a predictive maintenance program is the ability to evaluate the time between several failures. That allows you to pick the best cost-effective way of replacing your equipment.
5. It Boosts Your Return On Investment
The other benefit of predictive maintenance is that it significantly improves the general operation of processing and manufacturing plants.
The benefits accrued from the utilization of condition-based management programs offset the capital cost of the machine needed to implement the predictive program within the first couple of months.
The utilization of predictive maintenance methods, based on the collection of data, further minimizes the annual operating expenses of predictive maintenance techniques.
In this way, any company can get effective implementation in terms of costs by adopting this maintenance management program.
Regardless of predictive maintenance being a proven philosophy that has a lot of success stories, some of the implementations usually fail as well.
However, the main reason for that is the lack of management support and planning, which is vital to every successful program.
Predictive maintenance is a maintenance method used by many successful businesses. Due to its long-term and cost-effective benefits, your firm will be in a better position to always stay ahead of the competition.