The two main types of maintenance that come to mind are preventive and corrective maintenance. When we discuss the variety of available types of maintenance, Corrective maintenance is viewed as not ideal and should only be applied in the event of an emergency. In contrast, preventive maintenance is considered a positive thing and one that should be given priority. Furthermore, we typically connect preventive maintenance with something positive and something that should be given priority. However, there’s a third form known as predictive maintenance, and it has demonstrated benefits that may surprise you. The majority of companies don’t value this kind of maintenance.
Corporate Philosophy Predictive Maintenance
Predictive maintenance analyzes the condition of equipment and monitors the condition of equipment, and checks equipment to avoid costly repairs. Optimize machine and equipment use, enhance productivity, and lower expenses. It also aids the plant’s management plan. However, it’s not a replacement for traditional methods. Traditional programs rely on equipment repair and timely issue resolution and schedule jobs as needed. It will prevent unplanned downtimes and boost plant equipment availability. Here are the following benefits.
Cost-Cutting Maintenance
The cost of maintenance can be reduced by 50 to 80%. Maintenance costs include staff, overhead, replacement parts, tools, and other equipment.
Machine Failures Decrease
Regular monitoring of equipment and process systems can help reduce catastrophic failures of equipment by 55%. The analysis compares the frequency of unexpected equipment failures between predictive maintenance and condition monitoring. 90% savings are anticipated.
Repaired Quicker
Predictive maintenance minimizes repair and reconditioning time. Reduce MTTR by 60%. Before and after pre-planned maintenance, repair times are compared to calculate the average improvement. Monitoring and regularly analyzing machine conditions help maintenance technicians make repairs.
Lack of Spare Parts
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 could save more than 30%. Industrial plants can order replacement parts regularly and not have to store them.
Longer-Lasting Components
Avoiding catastrophic failures and identifying problems with systems and machines early can increase industrial plant machinery testing service life by 30%. The service life of machinery is predicted to rise after five years of proactive maintenance. The calculation covers the frequency of repairs, the severity of the damage, and the machine’s condition after repairs. Predictive maintenance based on the machine’s condition can reduce damage to the plant system and equipment. This reduces damage severity and prevents flaw spread, prolonging the lifespan of the equipment.
Predictive maintenance calculates MTF automatically (MTBF). This number helps determine if it is necessary to replace machinery to avoid expensive maintenance expenses. Major repairs or reconditioning of lower plant equipment’s MTBF. Predictive maintenance reduces MTBF over equipment life. If MTBF exceeds replacement costs, Replace the machine.
Production Increase
Condition-based maintenance can boost system availability. Increases can reach 30%. They are based solely on the availability of machines and not on process returns. A robust predictive system that includes monitoring of process parameters could help improve the efficiency of processing and manufacturing facilities.
Improvements in Safety
The early machine and system failure warnings decrease the risk of damage or death. Many insurance companies offer benefit reductions to factories using pre-planned maintenance based on condition.
Repair Verification
Vibration VIB analysis is a way to determine whether repairs to the existing machinery have resolved issues or led to strange behavior before the system is restarted. This can eliminate the requirement for a new closure to address poor maintenance. Schedule plant shutdowns using predictive maintenance data. Many businesses address serious flaws in annual shutdowns for maintenance or conduct preventative maintenance. Predictive data can help schedule repairs and other steps to prevent shutdowns.
Revenues
Predictive maintenance VIB management improves facility operation. The benefits of condition-based management cover the program’s equipment costs within 3 months. Predictive maintenance based on data can save you yearly operating expenses. The use of this method for managing maintenance will save the company money.
Despite the numerous successes of predictive maintenance, certain implementations fail. Insufficient planning and lack of managerial support is the main reason.
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