Predictive Maintenance (PdM), also known as condition-based maintenance, attempts to evaluate the condition of equipment by performing periodic or continuous (online) equipment condition monitoring. The ultimate goal of PdM is to perform maintenance at a scheduled point in time when the maintenance activity is most cost-effective and before the equipment loses optimum performance. This is in contrast to time- and/or operation count-based maintenance, where a piece of equipment gets maintained whether it needs it or not. Time-based maintenance is labor intensive, ineffective in identifying problems that develop between scheduled inspections, and is not cost-effective.
The “predictive” component of predictive maintenance stems from the goal of predicting the future trend of the equipment’s condition. This approach uses principles of statistical process control to determine at what point in the future maintenance activities will be appropriate.
Most PdM inspections are performed while equipment is in service, thereby minimizing disruption of normal system operations. Adoption of PdM can result in substantial cost savings and higher system reliability.
MEASURING THE BENEFITS OF PdM
Remember when diagnosing a machine’s condition required nothing more than a screwdriver and a good ear? Well, technology has come a long way.
These days, a host of high-tech tools make it possible to accurately determine the condition of equipment as it operates. This information can then be used to make precise maintenance decisions. The result is improved productivity, lowered maintenance costs, and extended machinery life.
ATS IMPROVES PRODUCTIVITY
By pinpointing problem areas and hot spots long before they cause critical shutdown, Predictive Maintenance (PdM) also increases productivity:
A major supplier to the U.S. government’s Defense and Aerospace Program avoided more than $1 million in downtime by doing an infrared thermography scan of its electrical distribution system.
ATS LOWERS MAINTENANCE COSTS
Cost savings are one of the major motivations behind most Predictive Maintenance (PdM) Programs:
One manufacturer of heavy machinery reduced its repair expenses by $1.7 million with Predictive Maintenance.
Current estimates suggest that the average plant not currently using vibration analysis to monitor equipment can reduce its maintenance budget by 20% with PdM. This can save your company thousands-or even hundreds of thousands-of dollars each year.
THE BENEFITS OF OUTSOURCING PdM
- No up-front capital required.
- Pay as you go with monthly Purchase Orders.
- You don’t have to worry about upgrades and software changes to PdM equipment-we take care of everything.
- Recognized leaders in Predictive Maintenance bring 156 years of combined expertise to your worksite.
- No vacations, no lay-offs, no transfers, bumping to other jobs, or light-duty restrictions.
- You get all of the service-none of the hassles.