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Predictive Maintenance

Predictive maintenance refers to using data-driven methods and sensors to analyze equipment condition and predict failures. It checks equipment during normal operation to identify defects early. Implementing a predictive maintenance program often results in reduced maintenance time and increased equipment uptime compared to reactive maintenance. Predictive maintenance uses sensors and IoT devices to continuously monitor baselines and collect conditional data on assets. When sensors detect anomalies outside normal parameters, work orders are automatically generated to address issues proactively.

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32 views

Predictive Maintenance

Predictive maintenance refers to using data-driven methods and sensors to analyze equipment condition and predict failures. It checks equipment during normal operation to identify defects early. Implementing a predictive maintenance program often results in reduced maintenance time and increased equipment uptime compared to reactive maintenance. Predictive maintenance uses sensors and IoT devices to continuously monitor baselines and collect conditional data on assets. When sensors detect anomalies outside normal parameters, work orders are automatically generated to address issues proactively.

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Predictive maintenance

Predictive Maintenance definition would be such as "Predictive Maintenance


(PdM) refers to the use of data-driven, proactive maintenance methods that
analyze the condition of equipment and help to predict when maintenance
should be performed".

What is Predictive Maintenance (PdM)?


Predictive Maintenance (PdM) is one type of maintenance that checks the
condition and performance of equipment during normal running operations. By
doing so, maintenance personnel can identify possible defects and fix them before
they result in a failure.

In fact, 91% of manufacturers who set up a predictive maintenance program saw


a reduction in maintenance time. As well as there is a 9% increase in equipment
uptime and a 20% expansion in the life cycle of old assets.

Predictive maintenance (PdM) is the most advanced type of maintenance currently


accessible. With time-based maintenance, companies risk performing too much
maintenance or not enough. And with reactive maintenance, they perform
maintenance when needed, but at the cost of unexpected downtime.

Similar to Preventive Maintenance (PM), predictive maintenance is a proactive


strategy that aims to get rid of asset breakdowns. But, unlike preventive
maintenance, predictive maintenance tries to predict when equipment might fail
with the use of IoT devices and sensors. This allows maintenance frequency to
lower down as possible to avoid a costly reactive strategy.

Predictive Maintenance video

Predictive Maintenance process


The first step in practising predictive maintenance is establishing baselines. You
need to monitor the assets’ conditional baselines and collect data before installing
sensors. That way, when you begin to collect conditional data, there is a “control” to
compare any abnormalities to.

To effectively collect the right data, predictive maintenance programs have to be


paired with the right condition-monitoring technology. In particular, a CMMS and
multiple IoT-enabled devices.

CMMS

The Internet of Things (IoT) plays a key role in the process of forming an efficient
predictive maintenance strategy. By collecting the necessary data from condition-
monitoring sensors, IoT devices can take that data and connect it to a maintenance
management system.

IoT sensors

From there, it’s simple - any time a piece of equipment performs outside of normal
parameters, the sensors trigger your predictive maintenance protocol. Typically, a
work order is generated in your CMMS and assigned to technicians so they can
perform any required repairs to address the anomaly.

Types of Predictive Maintenance


system
The types of information captured by predictive maintenance sensors can vary
depending on your equipment and machines.

Examples include:

Infrared Imagery
Infrared imagery analysis is not dependent on an asset’s rotational speed or
loudness. When temperature is a good signal of potential issues, infrared imagery
analysis is the most effective tool for doing predictive maintenance.

IR or infrared satellite imagery is a kind of temperature map. Through the use of


Infrared (IR) cameras, technicians can detect high temperatures (hot spots) for
worn components such as electrical wiring.

Acoustic Analysis

Acoustic Analysis can determine sounds related to machine friction and stress in
the ultrasonic range, it is used for maintaining electrical equipment that emits
subtler sounds and mechanical equipment. This type of analysis predicts imminent
breakdowns better than a vibration or oil analysis.

Seen as a cheaper alternative to ultrasonic imagery, acoustic analysis helps to


detect liquid, gas, and vacuum leaks.

Vibration Analysis

Vibration Analysis is for predictive maintenance inside manufacturing plants with


high-rotating machinery. Besides detecting looseness like in the example above,
vibrational analysis can also identify imbalance, misalignment, and bearing wear.

Sensors can be used to determine an increase or decrease in the vibration of


essential components such as pumps and compressors.

Oil Analysis or Acoustical analysis (sonic)


This type of analysis requires less money to implement and is used for low- and
high-rotating machinery. It’s particularly popular among lubrication technicians. The
acoustic bearing analysis is proposed for the lubrication technician and
concentrates on proactive lubrication measures.

Allows engineers to constantly check the condition of a machine’s oil lubricant and
determine if it has been compromised by other particles and contaminants.

How to implement predictive


maintenance
Before we implement predictive maintenance on the equipment floor, we present
ROI cases to management. We also trained maintenance staff and machine
operators on how to use the PdM technology. After this happens, true
implementation of the predictive maintenance process starts.

1. Establish baselines

The maintenance unit establishes acceptable condition limits for assets that will
have sensors. They have to decide which equipment is worthy to establish a
predictive maintenance system since it is a very costly process.

2. Install Internet of Things (IoT) devices

They attached the relevant sensor to the assets. For example, a vibration meter is
attached to a mechanical asset with gears and a temperature sensor is linked to a
boiler.

3. Connect devices to software

Then the IoT device is connected to a CMMS or remote dashboard, where data are
monitored and analyzed by maintenance engineers.
4. Schedule maintenance

Inspections processes are automatically triggered by CMMS software when the


predetermined condition limit is exceeded or the maintenance person monitoring
the dashboard schedules the inspection manually.

Example of Predictive Maintenance


(PdM)
To prevent unwanted downtime of the electric motor pump, the maintenance team
uses predictive maintenance technology. Because it’s a huge piece of mechanical
equipment that involves heavy rotations, the obvious choice is to monitor
vibrations with vibration meters.

The maintenance team attaches a vibration meter close to the pump’s inner
bearing. Whenever the vibration meter identifies a spike, the team reviews this new
data and schedules an inspection. The technician finds a loose ball-bearing and
repairs or replaces it.

Then they connect the vibration meter to its CMMS. Now, whenever the same spike
is spotted, a fault with the ball-bearing is predicted and it automatically triggered a
work order to perform the repair.

Advantages of Predictive Maintenance


1. Minimises unplanned downtime of mission-critical assets.
2. Reduces time spent on maintenance.
3. Increase the life expectancy of machines and equipment, in some cases by 20-
40%.
4. Reduces machine breakdowns and unexpected failures.
5. Minimises costs spent on labour, spare parts, and equipment.
6. Reduces stock of spare parts due to increased service life of assets.
7. Improves safety throughout the workplace for technicians and operators.
Disadvantages of Predictive
Maintenance
1. Detailed and time-consuming planning to ensure this maintenance approach is
deployed throughout each facility and details all assets.
2. Purchasing the right condition-monitoring equipment which can result in high
upfront costs.
3. Hiring skilled staff or training maintenance teams which can be expensive.

Preventive Maintenance vs Predictive


Maintenance
The difference between preventive maintenance and predictive maintenance lies in
how and when the data is being inspected and analysed. While a predictive
maintenance technician depends on monitoring and analyzing data from the
actual condition of the equipment in operation, a preventive maintenance
technician depends on historical data, averages, and life expectancy statistics to
predict when maintenance activities will be required.

The frequency of inspecting in preventive maintenance is high and requires a big


maintenance team. On the other hand, PdM relies on sensor devices, so the
maintenance team requirements are small.

Condition Based Monitoring vs


Predictive Maintenance
Condition-based monitoring is a type of PdM that relies on sensor data, such as
vibration monitoring systems, infrared analysis to measure the condition of
equipment over time while it is in operation. But the difference is - it only
performed maintenance when the dataset for predictive maintenance shows that
performance has decreased or a failure is likely.

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