The two main types of maintenance that come to your mind are preventive and corrective maintenance. When discussing the various types of maintenance, Corrective maintenance is viewed as ineffective and should only be used in emergencies. However, preventive maintenance is positive and should be considered a priority. In addition, we naturally consider preventive maintenance to be something positive and, therefore, ought to be given the top priority. But there’s another type of maintenance, called predictive maintenance, which has been proven to have advantages that may surprise you. Many companies do not value this kind of maintenance.
Corporate Philosophy Predictive Maintenance
Predictive maintenance analyzes equipment conditions and monitors or inspects equipment to prevent costly repairs. Improve the efficiency of equipment and machines to improve productivity, increase efficiency, and reduce expenses. It can also aid the plant’s management plan; however, it isn’t a substitute for the traditional management method. Traditional methods rely on equipment repair, prompt resolution of issues, and scheduling jobs according to the need. This will reduce unplanned downtimes and increase the availability of plant equipment. The following are benefits.
Maintenance That Cuts Costs
The cost of maintenance can be reduced by 50 percent. Maintenance costs include staff overhead, replacement parts, tools, and other equipment.
Machine Failures Decrease
Monitoring processes and equipment can reduce the risk of catastrophic failures by 55 percent. The study compares the rate of unexpected failures to equipment before and after predictive maintenance and condition monitoring. 90% savings are anticipated.
Predictive maintenance reduces the time needed for repair and reconditioning. Reduce MTTR by 60%. Before and after pre-planned maintenance, repair times are compared to determine the improvement average. Monitoring and regularly analyzing machine conditions helps maintenance personnel make repairs.
Parts Are Not Available
Identifying the problem with faulty parts like rotor balancing, machine alignment, and much more are tools, and skills of personnel that can reduce the time to repair and cost. The stockpile of spare parts could save you more than 30 percent. Industrial plants can purchase replacement parts when they need them rather than stockpiling them.
The prevention of catastrophic failures and the detection of the system and machine faults earlier extend machinery life in industrial plants by 30 percent. The life expectancy of machines is expected to increase after five years of proactive maintenance. The calculation covers repair frequency, the severity of the damage, and the machine’s condition following repairs. Predictive maintenance based on needs can prevent damage to plant systems and equipment. This minimizes the severity of damage and stops flaws from spreading, prolonging the life of the equipment.
Predictive maintenance automatically estimates MTF (MTBF). This statistic helps decide if to replace equipment to avoid costly maintenance costs. Reconditioning or major repairs lower plant equipment’s MTBF. Predictive maintenance reduces MTBF over equipment life. If MTBF is greater than replacement costs, Replace the machine.
Condition-based predictive maintenance increases the availability of the system. The increase can be as high as 30 percent. The improvement is based solely on the availability of machines and not on process returns. A comprehensive predictive program that includes monitoring of process parameters will help increase the efficiency of processing and manufacturing facilities.
Improvements to Safety
The early machinery vibration analysis and system failure warnings reduce the chance of injury or even death. Many insurance companies offer benefit reductions to factories that use pre-planned maintenance based on condition.
Vibration analysis will determine whether repairs to the existing machinery have solved problems or led to bizarre behavior before the system is restarted. This eliminates the necessity for a second shutdown to correct poor maintenance by looking for vibration monitoring companies. Schedule plant shutdowns using predictive maintenance data. Many businesses correct major faults during annual maintenance shutdowns or conduct preventative maintenance. Data that predicts the future can aid in scheduling repairs and other shut-down actions.
Predictive maintenance management can improve the efficiency of facilities. The benefits of condition-based management will cover the cost of equipment within three months. Predictive maintenance based on data can save you yearly operating costs. Implementing this approach to managing maintenance will save the company money.
Despite the numerous successes of predictive maintenance, however, there are some instances where it fails. The lack of planning and management support is the main reason.