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Predictive maintenance strategies can assist you to determine the condition of in-service equipment. This can help you estimate when to conduct maintenance.
This can save you money when compared to regular preventative maintenance. This is because you perform tasks only when there is a reason to. It is also called condition-based maintenance. You receive maintenance suggestions via estimates of the degradation state of your machine.
Predictive maintenance allows easy corrective maintenance scheduling. It also prevents unexpected equipment failure. t also increases safety as there are less accidents and environmental issues. And you are also optimising spare parts handling.
This differs from preventive maintenance. Preventative maintenance looks at the current condition of the machine. While predictive maintenance uses average or expected life statistics. So it predicts when maintenance is necessary.
To organise predictive maintenance, you need:
- Collection of data and preprocessing
- Fault detection
- Time-to-failure predictions
- Organising of maintenance sessions; and
- Optimising your resources.
It improves productivity as well as just-in-time in manufacturing. The aim is for products and systems to achieve and maintain near-zero breakdowns. Conduct health checks on your equipment to predict future faults. It is about making the most of assets.
Evaluation of your equipment is via periodic (offline) or continuous (online) condition monitoring.
The aim is to perform maintenance at a scheduled time, making it more cost-effective. So, before your equipment loses performance within a threshold. This means a reduction in unplanned downtime costs due to failure. These costs could be in the hundreds of thousands of dollars daily.
This is in contrast to time- and/or operation count-based maintenance. This involves maintaining machines whether they need it or not. It’s labour-intensive and ineffective in detecting issues that occur between inspections. For this reason, it is not cost-effective. Transform traditional ‘fail and fix’ maintenance strategies to ‘predict and prevent’ methods.
We predict the future of your machine’s condition. Statistical processing control evaluates the time to conduct maintenance.
Predictive inspections can occur at the same time as your service session. Use predictive maintenance in conjunction with preventive maintenance.
The future aim is for data to be in a computerised system that receives the machine condition data. The system then activates maintenance planning, execution of work orders, reporting, etc.
Manufacturing machinery maintenance:
- Early fault detection and diagnosis
- Collecting big data from the Internet of Things sensors in factories.
- Algorithms for collected data detect and predict signs of failures before they happen.