Maintenance strategies of the past are no match for today's fast-paced manufacturing landscape, mainly because machine reliability is now more critical than ever for meeting lead times. So how do we keep our machines healthy and performing at top quality? Predictive maintenance, the next-generation machine maintenance approach, allows you to develop more intelligent maintenance strategies to forecast when maintenance should occur.
Let's explore the fundamental concepts of predictive maintenance and shed some light on how to get started. Keep reading or watch our videos below!
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Preventive maintenance is another maintenance method that schedules regular maintenance activities; however, it addresses a more aggressive machine operation where machine wear is accelerated and requires more scheduled maintenance. It requires an excess of stock and manpower to perform inspections properly, and parts often have to get replaced too soon in their life cycle to avoid unnecessary downtime. We dive deeper into these, plus other maintenance strategies, in another blog post - Maintenance Strategies Explained.
The most significant advantage of predictive maintenance is its ability to provide historical data on system performance. This valuable data allows your business to assess whether its systems operate within capacity or need adjustments to meet evolving challenges. By understanding the actual stress components, companies can preemptively plan maintenance tasks and minimize the risk of system failure. See a motor's performance slowly dipping? Now you can order the replacement well before production loss or total failure, and schedule the replacement during routine downtime.
Systems running continuously under varying loads, such as those in 24/7 operations, greatly benefit from predictive maintenance. Mainly because electrical and mechanical components, including hydraulics and electrical motors, are particularly prone to stress and wear. Predictive maintenance sensors can monitor critical parameters like insulation resistance, temperature & vibration, thermal condition monitoring, and bearing wear and alert personnel at set parameters using a simple check engine light approach, allowing maintenance personnel to intervene long before a total system failure occurs. This proactive approach optimizes planning, minimizes disruptions, and ensures production continuity.
Aside from the operational advantages, predictive maintenance also contributes to environmental sustainability. You and your company can reduce the carbon footprint associated with rushed handling, and separate product orders can be reduced by integrating maintenance needs into regularly scheduled shipments. Additionally, companies can leverage remote monitoring capabilities to access machine data from anywhere globally, minimizing the need for on-site visits. Predictive maintenance also helps prevent environmental disasters caused by system failures and machine wear. As parts break down and systems fail, that's when toxic materials get leaked into waterways or the soil, or harmful substances released into the atmosphere from substance break-down.