How does Predictive Maintenance work?

Predictive maintenance is an engineer’s best friend and a powerful tool for optimizing platforms in a manufacturing facility. Instead of having scheduled maintenance done on a predetermined timeframe, predictive maintenance uses data and technology to specify when maintenance needs to be completed to prevent costly breakdowns accurately. It works by collecting data from a facility’s various components and then using it to determine when parts need maintenance, as well as use algorithms or Artificial Intelligence (AI), if necessary.

Predictive maintenance can help save time and money, improve efficiency in the facility, and help ensure that safety standards are adhered to throughout the lifecycle of all machines.

Predictive Maintenance Technologies

Some of the most effective predictive maintenance technologies include oil analysis, vibration monitoring, thermography, emissions testing, and lubricant analysis.

Oil analysis is a reliable method for determining whether machinery runs in optimal condition.
Vibration monitoring tracks any irregularities that may indicate an impending problem.
Thermography uses infrared imaging to detect temperature anomalies which can alert engineers to possible component damage.
Emissions testing helps see excessive emissions from boilers and engines associated with excess oil burning or fuel sludging.

Lubricant analysis provides information about oil degradation and contamination, so trained professionals can develop strategies to prevent wear and tear on machinery components.

All these technologies are essential in keeping machinery up and running correctly over time.

Predictive Maintenance Vs. Preventive Maintenance

Predictive maintenance and preventive maintenance are two critical yet distinct approaches to improving the reliability and longevity of industrial machines.

Predictive maintenance utilizes data from sensors and predictive algorithms to anticipate when a device needs to be serviced. This proactive approach allows for routine check-ups based on machine usage, leading to increased operational efficiencies and cost savings.

Preventive maintenance focuses on adjusting and calibrating machines according to a regular schedule and parts such as bearings and drives being lubricated regularly. This tried-and-tested approach is designed to detect irregularities while machines run at average speed and behavior, enabling engineers to take corrective action before faults appear.

Benefits of Predictive Maintenance

Predictive maintenance is a versatile tool that can provide many benefits to engineers, both technically and financially.

1.Improves Equipment Life
Predictive advanced analytics capabilities can diagnose systemwide issues with up to 95% accuracy, which helps engineers troubleshoot problems long before they occur.

2.Provides Cost Savings
Predictive maintenance provides cost savings through reduced machine downtime as predictions of necessary maintenance allow for scheduled repairs and preventive actions.

3. Supports sustainability initiatives.
Predictive maintenance supports sustainability initiatives by optimizing performance while reducing energy consumption and waste materials generated during more frequent repairs.

With all of these advantages, predictive maintenance provides an invaluable service for engineers keeping tabs on the performance of assets.

6 Steps for Establishing a Predictive Maintenance Program

Step 1: Assess Your Maintenance Needs. Before establishing a predictive maintenance program, assessing your organization’s current maintenance needs is essential, as identifying which assets would benefit most from this strategy.

Step 2: Gather Data on Assets. Once you have identified the assets included in the predictive maintenance program, you will need to collect and analyze data related to their performance.
Step 3: Analyze the Data. Once you have gathered enough data on your assets, you will need to analyze them using specialized software designed for predictive analytics.
Step 4: Develop an Action Plan for Maintenance Activities. Once the analysis is complete and potential maintenance issues have been identified, you can develop an action plan for addressing them proactively rather than reacting after a breakdown occurs.
Step 5: Implementing the Program and Monitoring Performance Results. In addition to tracking any improvements in reliability or uptime levels due to the implementation of this type of system, it is also essential to monitor any changes in labor costs or materials needed.
Step 6: Create a checklist for predictive maintenance. Once predictive maintenance has been implemented, creating a checklist of tasks and activities that should be completed on a regular program’s continued success is crucial.

FAT FINGER as your Predictive Maintenance Partner

Establishing a predictive maintenance program is critical for engineering, facilities, and manufacturing environments. FAT FINGER helps you stay on top of your maintenance management program to create an efficient system.

With FAT FINGER‘s intuitive interface and easy-to-use checklist, you can ensure that all your machines are running as smoothly as possible. FAT FINGER ensures that regular inspections are conducted to identify any potential problems before they become severe enough to cause a breakdown of the machine. It also allows engineers to easily keep track of their maintenance tasks and change parts to prevent unforeseeable faults from occurring.

Take the predictive maintenance process to the next level and invest in FAT FINGER, with the predictive maintenance workflow that will maximize your organization’s performance and efficiency. Click here to get started today!

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