The two main types of maintenance that come to your mind are preventive and corrective maintenance. When discussing the various types of maintenance available in the world, corrective maintenance is often viewed as something that is not very beneficial and should only be used in an emergency. Contrarily, preventive maintenance is considered a positive thing and must be given priority. Moreover, we naturally connect preventive maintenance with something positive that should be prioritized. However, another type of maintenance, known as predictive maintenance, has demonstrated benefits that will be awe-inspiring to you. Companies frequently undervalue this sort of maintenance.
Corporate Philosophy Predictive Maintenance
Predictive maintenance examines equipment status, monitors or inspects equipment, and checks equipment to avoid costly repairs. Improve the efficiency of equipment and machines, enhance productivity, and reduce costs. It also helps a plant’s management program, but it doesn’t replace the methods used in the past. Traditional methods rely on equipment repair, timely resolution of issues, and scheduling jobs as needed. It can prevent unexpected downtimes and increase the availability of plant equipment. These are the benefits.
Cost-Saving Maintenance
Maintenance expenditures can be cut by 50 percent. Maintenance expenses can include personnel overhead, replacement parts, equipment, tools, and other equipment.
Machine Failures Decrease
Monitoring of processes and equipment can decrease catastrophic equipment failures by 55%. The study compares the incidence of unexpected equipment failures before and following predictive maintenance and condition monitoring. 90% savings are anticipated.
Repaired Quicker
Predictive maintenance can reduce the time needed for repair and recondition. Reduce MTTR by 60%. Before and after predictive maintenance, repair times are compared to estimate the average improvement. Regular monitoring and analysis by vibration specialists of machine performance helps maintenance staff plan repairs.
Insufficient Spare Parts
Ensuring that you know the components, tools, and skills of personnel help reduce the time for repair and expense. Stocking spare components will save more than 30%. Industrial plants can place orders for replacement parts as needed and not have to store them.
Longer-Lasting Components
Avoiding catastrophic failures and identifying machine and system faults early can increase maintenance life for machinery used in industrial plants by 30%. Machine service life is projected to increase following five years of prescriptive maintenance. The calculation includes repair frequency, the severity of the damage, and machine condition after repairs. Predictive maintenance based on needs can prevent damage to plants and equipment. This minimizes the severity of damage and helps prevent flaws from spreading, prolonging the life of the equipment.
Predictive maintenance estimates MTF automatically (MTBF). This information helps determine if it is necessary to replace machinery to avoid expensive maintenance expenses. Reconditioning or major repairs lower plant equipment’s MTBF. Predictive maintenance reduces MTBF over equipment life. If MTBF exceeds replacement cost, you should replace the machine.
Production Increases
Condition-based predictive maintenance increases system availability. The increase can be as high as 29 percent. Improvements are based only on machine availability as opposed to process returns. A thorough predictive program that includes monitoring of process parameters can help boost the productivity of manufacturing and processing facilities.
Safety improvements
Early machine analysis and troubleshooting and system failure warnings reduce the chance of damage or death. Several insurance companies offer benefits reductions for factories using pre-planned maintenance based on condition.
Repair Verification
Vibration testing services analysis will determine whether any repairs to existing equipment have resolved issues or led to unusual behavior before the system starts. This eliminates the necessity for a second shutdown to fix poor maintenance. Schedule plant shutdowns using predictive maintenance data. Many firms correct serious issues during annual maintenance shutdowns or conduct preventative maintenance. Predictive data can help plan repairs and other steps to prevent shutdowns.
Revenues
Predictive maintenance management can improve the efficiency of facilities. Condition-based management benefits provide the program with the equipment cost within 3 months. Predictive maintenance based on data can save you yearly operating costs. Implementing this method of managing maintenance can save the factory money.
Despite the numerous successes of predictive maintenance, however, there are some instances where it fails. Lack of planning and managerial support is the primary reason.
