Benefits of a Predictive Maintenance Program

by | Aug 18, 2014 | Predictive Maintenance

For this blog post, I’m going to take a few steps back.  Instead of focusing on a specific technology, trend, or approach to predictive maintenance (PdM), I’m going to cover some of the very basic benefits that can be realized with a successful PdM program.  For those of you that may be new to predictive maintenance or are considering some new strategies at your facility, this may give you some new insight into why you should be implementing these practices.

So, what are a few things that you can expect when you implement a successful PdM program at your facility?  Here are a few examples of what others have accomplished:

  • Decreases in maintenance costs (both labor and equipment)
  • Decreases in unplanned/unscheduled work
  • Increases in uptime
  • Increases in efficiency and productivity
  • Improved equipment reliability
  • Improvement in quality and repeatability
  • Decreases in energy costs
  • Reduction in spare parts inventory
  • Improved safety environment
  • Many more…

While this list does not include every possible scenario, it does provide a good representation of what can be expected from an effective predictive maintenance program.  Every facility that has made a commitment to a PdM program has had their own set of circumstances that have lead them to that decision.  However, it almost always boils down to money.  Facilities that have implemented a successful program typically see a maintenance budget reduction anywhere from 20%-50%.  When you combine that with some of the other positive effects of a PdM program, the results can be very impressive.

When presented in this format, the decision to implement a PdM program seems to be an easy one.  While that may be the case, it doesn’t make the transition from a “run to failure” to a predictive approach completely seamless.  There will absolutely be difficulties and setbacks in this journey.  Take these challenges head on and keep the end game in mind as you hurdle obstacle after obstacle.  When you can look at your facility and identify some of the above benefits yourself, you’ll know you’re on the right path.


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