Predictive maintenance is a useful tool in the technological world of business. It uses analytics to identify equipment abnormalities and potential defects. It helps companies save time and money, improves system reliability, reduces downtime, and boosts efficiency.
How Does Predictive Maintenance Work?
Predictive maintenance uses historical and real-time data to anticipate issues before they happen. It considers your equipment’s condition and performance, analyzes work orders, and benchmarks MRO (maintenance, repair, and operation) usage. It processes the data to determine which areas need attention.
The solution uses several technological tools. Its software integrates IoT, artificial intelligence, and integrated systems. It connects various fields to enable data sharing and analysis that leads to valuable insights.
The predictive maintenance process is as follows:
- The technology familiarizes itself with the equipment and signs of failure
- It establishes a routine for monitoring the equipment’s condition
- It issues regular reports on the equipment’s condition
If an issue is detected, it will:
- Create a work order
- Schedule service
- Ensure parts and labor are available
- Perform repairs if possible
- Close the work order
What are the Benefits of Predictive Maintenance?
Reduces Downtime
Equipment breakdowns lead to downtime. Teams must wait while equipment is repaired. Businesses can lose days of productivity, disappoint customers, and fall behind the competition.
Predictive maintenance addresses issues early so they can be dealt with before they lead to downtime. They allow businesses to maintain a high level of productivity.
Saves Money
An equipment breakdown can lead to expensive repairs. Predictive maintenance detects issues before they occur. It minimizes costs so you can increase profitability.
Predictive maintenance can lead to larger up-front costs, but it tends to save you money in the long run.
Improves Operational Efficiency
Systems that are well-maintained are more efficient. They complete tasks faster so your company can be more productive. They also reduce time spent dealing with technicians and waiting for service to ensure smoother operations.
Allows for Better Supply Inventory Management
Many companies will stock up on spare parts so they will be available when systems break down. Some of these parts go unused. Predictive maintenance indicates which parts will be needed so you can budget accordingly.
Optimizes Maintenance Costs
Businesses often invest in unnecessary maintenance. PdM lets you know when maintenance is needed so you don’t overspend.
Increases Equipment Lifetime
Well-maintained machines tend to last longer. Statistics show that machinery that is repaired early can last 30% longer than machinery that isn’t as well maintained.
Verifies Repair Efficacy
Predictive maintenance includes features like vibration and oil analysis, equipment observation, thermal imaging, and sensors that can confirm a repair’s success before the equipment resumes functionality.
What is the Difference Between Predictive Maintenance and Preventative Maintenance?
Predictive maintenance and preventive maintenance can both save money and boost productivity in a business setting, but they are not the same. Here are some key differences to consider.
Predictive Maintenance
- Proactive maintenance
- Uses predictive technology to predict problems before they lead to equipment failure
- Focuses on data concerning the equipment’s performance
- Improves supply inventory efficiency by ensuring parts are not replaced too soon or run to a point of severe damage
- Prevents and minimizes downtime
- Uses advanced technological tools like vibration analysis, oil analysis, and infrared thermography alongside data analytics software
Preventative Maintenance
- Planned maintenance
- Automated maintenance scheduling
- Provides an overview of your system’s health and performance
- Often requires downtime
- Utilizes manuals and maintenance checklists following standard operational procedures
Preparing for Predictive Maintenance
Predictive maintenance has a leg up on preventative maintenance because it eliminates downtime and manual processes. However, it presents some challenges. Businesses can prepare teams through the following strategies.
- Training: Predictive maintenance requires data analysis and software integration. Teams must be trained to work with PdM tools to ensure their equipment runs smoothly.
- Avoid Over-reliance on Technology: PdM technology can reveal various issues and prevent them from turning into bigger problems, but it should not replace the human element. Workers should look out for signs of wear and tear that may not be revealed through automated systems.
- Cost Management: Predictive maintenance typically requires a large up-front investment, but it can save companies money in the long run. Businesses that budget wisely will overcome financial hurdles.
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Additional Resources
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