Before knowing how does Predictive Maintenance work, we must have a glimpse of its introduction. Predictive Maintenance is the maintenance where the conditions, as well as the performance of the equipment, are monitored during normal operations. It is done to reduce the failures. Here, the frequency of maintenance tasks is kept low, and unwanted preventive maintenance is eliminated to keep the cost low.
Types of Predictive Maintenance
There are different types of Predictive Maintenance that we have explained below. We will discuss each of the given types that will help you to explore more about it:
- Vibrational analysis
- Acoustical analysis (Sonic)
- Acoustical analysis (Ultrasonic)
- Infrared analysis
1. Vibrational analysis
The vibrational analysis is the go-to type of analysis for the predictive maintenance that is inside the manufacturing plants with the high-rotating machinery. It is longer than others condition monitoring and it is also cost-effective. It can discover an imbalance, misalignment, as well as bearing wear.
2. Acoustical analysis (Sonic)
It is another type of Predictive Maintenance that requires very little money for implementation. It can be used for low- as well as high-rotating machinery. This is popular among lubrication technicians. As per some references, it is too much similar to the vibration analysis. Its focus is not to detect the rotating equipment failure. It can measure and monitor the vibrations at discrete frequencies as well as recording data for trending purposes.
3. Acoustical Analysis (Ultrasonic)
When the sonic acoustical analysis borders on the line of predictive maintenance, the ultrasonic acoustical analysis can be easily used for predictive maintenance efforts. It can simply identify the sound that is related to the machine friction as well as stress in the ultrasonic range. It is also used for electrical equipment that can emit subtler sounds.
4. Infrared Analysis
Infrared Analysis is not dependent on an asset’s rotational speed. It is also suitable for various types of assets. The temperature is a great indicator of the potential issues and the infrared analysis is the cost-effective tool that is used for predictive maintenance. It can help to find the problem that is related to cooling, motor stress, and airflow.
How Does Predictive Maintenance Work?
Predictive Maintenance operates the periodic equipment condition monitoring in order to calculate the condition of the particular equipment. In most cases, this maintenance is performed when the equipment is processing normally as it minimizes the disruption of daily operations. The maintenance strategy would be beneficial in the future also.
How to Implement Predictive Maintenance?
After knowing how does Predictive Maintenance works, you must know how to implement it. In order to implement Predictive Maintenance, you have to follow the given steps that we have provided. Maintenance staff, as well as machine operators, are trained with the PdM technology. Now, the implementation will start:
1. Establish Baselines
First of all, the management team has to establish acceptable condition limits for assets.
2. Install Internet of Things (IoT) Devices
Now, this is time to install the Internet of Things Devices. The team will affix the relevant sensors to the assets. The vibration meter should be affixed with temperature sensors and gears.
3. Connect Devices to Software
Let’s proceed to the next step where the IoT devices would be connected to the CMMS where data is analysed and collected.
4. Schedule Maintenance
Inspections would be triggered by the CMMS at the time when the condition limit is increased or there could be another case that the person monitoring the dashboard schedules the inspection manually. There are different types of IoT Sensors by Monnit.
Benefits of Predictive Maintenance
Predictive Maintenance helps to improve the maintenance as well as reliability program. With the help of this technology, as well as the best practices in order to streamline processes and increase productivity. There are different benefits of Predictive Maintenance, here we have explained the complete benefits of this maintenance that will help you to explore more about it:
- It can increase the assets uptime by 30% as well as reducing unexpected failures by 55%.
- The streamlining maintenance costs through reduced labor, equipment, as well as inventory costs.
- It can also improve safety.
ROI of Predictive Maintenance
According to a reference, a well-orchestrated predictive maintenance program would but eliminate catastrophic equipment failures. When it is compared to a preventive maintenance program, the cost savings are 8 to 12 percent higher and it is compared to a reactive maintenance program. The cost savings range from 30 to 40 percent. Other numbers stated by the Department of Energy include:
- Return on investment: 10 times
- Reduction in maintenance costs: 25% to 30%
- Elimination of breakdowns: 70% to 75%
- Reduction in downtime: 35% to 45%
- Increase in production: 20% to 25%
Example of Predictive Maintenance
To understand how does Predictive Maintenance work, let’s understand it with an example:
There is a centrifugal pump motor in the coal preparation plant. It is an important asset for daily operations. In order to avoid unscheduled downtime, the maintenance team decided to use predictive maintenance technology. It is a large piece of mechanical equipment that performs heavy rotations. Now, things are about monitoring the vibrations with the vibration meters. The team also attaches the vibration meter and closes to the pump’s inner bearing as well as establishes a normal baseline measurement.
It can visualize through the waveform graph. After some time, the vibration meter will indicate a spike in acceleration. The team will review the new data as well as the schedule and inspection. The technicians who will perform the inspection will find a loose ball-bearing as well as repair it. After this, the team will connect the vibration meter to its CMMS. When the sam spike would be identified, a fault with the ball-bearing would be predicted. With this example, you can easily understand how does Predictive Maintenance work.
We have explained the complete information regarding how does Predictive Maintenance work. Predictive maintenance is great maintenance that can monitor the conditions of assets by using the sensors devices. There are different types of predictive maintenance that can be used according to the requirements. Predictive Maintenance can also provide an ROI that can help in reducing costs.