The two most common types of maintenance that come to your mind are preventive and corrective maintenance. When discussing the many types of maintenance, corrective maintenance is thought of as something not so good and should only be used in an emergency. In contrast, preventive maintenance is considered a positive thing and must be considered a priority. Additionally, we usually connect preventive maintenance with something positive and one that ought to be prioritized. But, there’s a third form known as predictive maintenance, and it has proven advantages that may surprise you. The majority of companies don’t value this kind of maintenance.
Corporate Philosophy Predictive Maintenance
Predictive maintenance analyzes equipment condition, inspects or monitors equipment, and checks equipment to prevent costly repairs. Maximize equipment and machines, boost productivity, improve efficiency and decrease expenses. It can also aid an organization’s management system; however, it’s not a replacement for traditional methods. Traditional management programs depend on equipment repair and timely issue resolution and plan jobs according to what is needed. This will reduce unplanned downtimes and improve the availability of plant equipment. These are the benefits.
Maintenance Cost-Cutting
Maintenance costs can be cut by 50 50%. The maintenance costs include staff, overhead, replacement parts and tools, and other equipment.
Machine Failures Decrease
Monitoring machinery and process systems can reduce the risk of catastrophic failures by 55 percent. This comparison is based on the rate of unexpected failures to equipment before and after pre-planned maintenance and monitoring of the condition. 90% savings are projected.
Repairs Made Faster
Predictive maintenance can reduce the time for repairs and reconditioning. Reduce MTTR by 60%. Before and after the predictive maintenance process, repair times are compared to calculate the average improvement. Monitoring and analyzing regularly of machine performance helps maintenance staff to plan repairs.
Parts Are Not Available
It is important to identify the defective component, and the tools and personnel skills cut down on repair time and expenses. In spare stocking components, you can save over 30%. Industrial plants can order spare parts on this site at the time of need and do not have to store them.
Longer-Lasting Components
Preventing catastrophic failures and detecting the system and machine faults early can increase maintenance life for machinery used in industrial plants by 30 percent. The service life of machinery is predicted to increase following five years of prescriptive maintenance. The calculations include the frequency of repairs, the severity of the damage, and machine condition following repairs. Condition-based predictive maintenance helps prevent damage to plants and equipment. This reduces damage severity and reduces flaw spread, prolonging the equipment’s life.
Predictive maintenance is a method of estimating MTF automatically (MTBF). This number helps determine if to replace equipment to avoid the expense of maintenance. Reconditioning or major repairs lower plant equipment’s MTBF. Predictive maintenance reduces MTBF over equipment life. If MTBF is greater than replacement costs, then replace the machine.
Production Increase
Condition-based predictive maintenance boosts system availability. This can go up to 30%. Improvements are based only on machine availability and not process return. A well-designed predictive program that includes process parameter monitoring can boost the efficiency of processing and manufacturing facilities.
Safety Improvements
The early vibration analysis of rotating machines and system failure warnings reduce the chance of injury or death. Many insurance companies offer benefit reductions for factories with conditions-specific predictive maintenance.
Repair Verification
The vibrations analysis and monitoring can determine if repairs to existing machinery have solved problems or led to unusual behavior before the system restarts. This can eliminate the requirement for a new closure for maintenance issues. Schedule plant shutdowns using predictive maintenance data. Many businesses correct major faults in annual shutdowns for maintenance or carry out preventive maintenance. Predictive data can help schedule repairs and other activities to stop the shutdown.
Revenues
Predictive maintenance management can improve facility operations. The benefits of condition-based management provide the program with the equipment cost within three months. Data-driven predictive maintenance saves yearly operating costs. Using this method for managing maintenance can help save money for the factory.
Despite the many successes of predictive maintenance, certain implementations fail. Insufficient planning and lack of managerial assistance is the key factor.
