Predictive Maintenance Strategy: 4 Applications, Disadvantages/Advantages

Predictive maintenance strategy is a method of analyzing data to predict when equipment will need repair or replacing. It’s also known as Condition-based Maintenance and Predictive Analytics. The process uses historical data from the asset in question, such as vibration levels, temperature and speed readings, among others. This information helps identify trends that signal the impending failure of an item before it happens.

There are 4 applications of predictive maintenance strategy:

  • Condition-based maintenance: Predictive maintenance strategy helps to determine when equipment will need repair or replacing. This reduces the need for sudden, unexpected repairs that can cost up to 50% more than a planned repair in advance.
  • Preventative maintenance: Predictive maintenance strategy helps to determine when equipment will need repair or replacing. This prevents equipment from failing and causing a disruption to business operations by reducing unscheduled downtime due to unexpected mechanical failure.
  • Equipment diagnostics: Predictive maintenance strategy helps to determine when equipment will need repair or replacing. The data collected from predictive analytics is used to diagnose and report on the condition of the asset without incurring any risk of damage or injury in the process.
  • Fault detection: Predictive maintenance strategy helps to determine when equipment will need repair or replacing. The data collected from predictive analytics is used in conjunction with diagnostic tools for fault detecting and diagnosing the cause of a failure before it occurs.

Disadvantages:

Predictive maintenance strategy can take time to analyze historical data on an asset which may create delays in initiating repairs that could have been planned ahead of time. It’s important for organizations using this method to plan strategic downtime periods so as not to interrupt customer service operations during peak times such as weekends and evenings. Another disadvantage is that some assets are difficult if not impossible to monitor with data-gathering sensors.

  • Less Downtime – Reduced Costs Associated With Unplanned Repairs By Up To 50%

Advantages:

Predictive maintenance strategy is a cost effective way of maintaining assets without the need for excessive unscheduled downtime, unexpected repairs or errors due to human error and preventative service can be less costly than waiting until an item fails to fix it before moving on.

  • Higher Cost – More Data To Collect And Analyze – Requires Predictive Analytics Software 

Who should use predictive maintenance strategy?

Companies that want lower costs associated with repair and replacement and increased uptime for their equipment will benefit from implementing this type of predictive analytics system within their organization. These types of analytical solutions are most useful in organizations where time means money such as manufacturing plants who rely heavily on production schedules being met. The increased reliability gained by using these systems also translates into higher customer satisfaction because they are more likely to receive deliveries on time and have a greater number of products in stock.

Who Shouldn’t Use A Predictive Maintenance Strategy?

As tempting as it may sound, we recommend that small businesses avoid these types of approaches at first due to additional data collection requirements which can take away from time spent on other priorities.

Small businesses should instead focus on developing a maintenance plan for their machines, so they are able to implement the strategy once it becomes more feasible.

How to implement a predictive maintenance strategy:

The Maintenance Plan: A preventive machine maintenance plan is important in order to reduce downtime affecting your production process and ensure availability by staying ahead of potential problems that could cause down time or unexpected repair costs. We’ll discuss what some basic components might be below:

  • Some basic components to consider for this plan include: -A regular schedule for maintenance, including inspection or cleaning of the machine and its parts. Regularly changing any filters that might be necessary in order to remove contaminants from the air. Inspecting connections between pipes and hoses so they are not coming loose or leaking fluids.
  • Any other preventative steps you feel will help prolong your machinery’s use can also be included if deemed appropriate by a trained professional.

The Importance Of Preventive Maintenance: Simply put, machines need care like anything else living on this Earth does and it is up to us as their owners/designers/programmers etc., to provide them with optimal conditions if we want to get the most out of them.

Simply put, machines need care like anything else living on this Earth does and it is up to us as their owners/designers/programmers etc., to provide them with optimal conditions if we want to get the most out of them.”  It goes without saying that a machine’s life span can be significantly shortened by neglecting its maintenance requirements. Neglect will not only lead to higher costs in terms of downtime or unplanned repairs but also lost production time due to lack of availability. In order for machines (or any other type) running machinery businesses – oil rigs, power plants, factories; there are many examples – can continue operating at maximum efficiency, emergencies should be prevented through routine inspections, regular maintenance and timely repairs.

  • A machine’s life span can be significantly shortened by neglecting its maintenance requirements. Neglect will not only lead to higher costs in terms of downtime or unplanned repairs but also lost production time due to lack of availability. In order for machines running machinery businesses (oil rigs, power plants, factories)
  • there are many examples:
  • to continue operating at full efficiency during emergencies should be prevented through routine inspections, regular maintenance and timely repairs.