What is Predictive Maintenance?
What Is Predictive Maintenance?
Maintenance is a tough and hectic job for the maintenance personals in the plant premises across all industries.
The constant fear of unexpected breakdown with the conventional maintenance practices such as Preventive Maintenance(A run hour or Periodic) or Reactive Maintenance is always there.
Unexpected breakdowns lead to high downtime of critical machines that effects the production process and causing huge financial losses for the industrial firms worldwide.
So, you can find the solution for these obstacles in a new and better way of maintenance which is known as Predictive Maintenance.
To know what is predictive maintenance, why industries should adopt it, how it is done, and how it is different from the conventional maintenance methods, continue reading below.
Predictive Maintenance Definition
Predictive Maintenance can be defined as a type of maintenance method that uses condition monitoring tools to create a maintenance or repair plan prior to the full machine failure or breakdown.
The assets/machines are here wirelessly monitored to detect the developing faults or early failures in them. The maintenance or repair of those assets is then planned accordingly.
How Predictive Maintenance is done?
Predictive Maintenance utilizes the Internet of Things (IoT) for its existence and functionality.
IoT or Internet of things, in a brief, can be defined as an ecosystem of interrelated physical devices provided with unique identifiers (UIDs), which makes them capable of communicating within themselves without any human-to-human or human-to-device interaction.
Read more on The Internet of Things.
Predictive Maintenance technology uses a combination of sensors and software. A sensor or combination of two or more sensors is required to accurately monitor essential parameters like Vibration, Temperature, Magnetic Flux, Ultrasound, etc which are later stored and analyzed with the help of software modules integrated with the sensors.
Read about the ioEYE Predict IoT Vibration Sensor that offers multiple sensors packed into one.
Read about the ioEYE Predict Cloud Platform for Predictive Maintenance that predicts machine failures.
The acceptable boundaries of parameters for a healthy machine operation are defined within the system.
This allows the system to generate an alert or trigger an email notification whenever those values exceed their threshold limits.
Where Predictive Maintenance can be deployed?
All types of critical rotating or reciprocating machines that have
High repair time due to Preventive or Reactive Maintenance,
High maintenance or repair costs involved
Direct impact on the production cycle
are good candidates for Predictive Maintenance Solution.
So you can use this for your high capacity Motors, Pumps, Compressors, Fans, Gearboxes, etc.
What are the conventional maintenance methods used in industries?
The conventional Maintenance methodology that is currently followed across the manufacturing industries is the Preventive Maintenance, which comprises run-hour maintenance and Periodic (Scheduled) Maintenance.
Reactive Maintenance or repairing an asset after its total failure is also performed but on smaller or non-critical machinery.
How Predictive Maintenance differs from Conventional Maintenance strategies?
In Predictive or condition-based maintenance, you perform your repair activities only when your machine shows major signs of its deterioration.
The machine deterioration can result be either due to its constant operation or its mishandling by the operator.
The PdM system provides you with essential alerts with the help of which the maintenance or repair work is then performed.
What are the benefits of utilizing Predictive Maintenance Technology?
The Predictive Maintenance strategy reduces the downtime impact of the critical rotating machines.
This, in turn, reduces overall maintenance costs and also increases the productivity of those assets. It also helps in maintaining the spare parts or inventory which would be required during the repair works.
The PdM makes this all possible as here you are performing the maintenance on your machines only when it is required that is, on receiving alerts indicating the faults developing in those assets.
This eliminates the sudden unplanned machine maintenance as now maintenance will always be scheduled and when needed.
Recent studies have shown that using Predictive Maintenance programs can provide up to 10 times of ROI, as it reduces
maintenance costs by (25-30) %,
sudden breakdown chances by (85-90) %
downtime of machines by (30-35) %,
as compared with the conventional run-hour or periodic type of maintenance.
Read more about the Advantages of Predictive Maintenance.