December 15, 2023
Equipment maintenance is usually done according to a pre-prepared plan, or less frequently in cases of breakdowns that make further operation impossible or dangerous. Both approaches have their advantages, but in the first case, the material costs are not always justified, as the equipment may still have resources for further operation, while in the second case, it requires costs to restore functionality.
An alternative is Predictive Maintenance, which utilizes the Internet of Things and data analysis to detect operational anomalies and defects for the purpose of planning equipment maintenance and repairs.
Differences between Predictive Maintenance and Preventive Maintenance.
| Aspect | Predictive Maintenance | Preventive Maintenance |
|---|---|---|
| Definition | Uses data analysis and monitoring to predict the possibility of equipment failure and allows for timely maintenance. | Planned maintenance performed at regular intervals to prevent failure or degradation of equipment. |
| Approach | Based on the equipment’s condition, relies on real-time data and advanced analytics to detect early signs of equipment failure. | Time-based, where maintenance is done based on pre-determined schedules or fixed intervals. |
| Objective | Minimizes unplanned downtime and reduces maintenance costs by performing maintenance only when necessary. | Enhances equipment reliability and lifespan by preemptively addressing potential issues before failure occurs. |
| Data Usage | Utilizes sensor data, performance indicators, and historical records to identify patterns and predict equipment failure. | Relies on maintenance plans, service history, and manufacturer recommendations to schedule routine maintenance tasks. |
| Maintenance Timing | Maintenance is triggered based on detected anomalies or specific thresholds indicating an impending failure. | Maintenance tasks are performed according to pre-defined schedules, often at regular intervals (e.g., monthly, quarterly, annually). |
| Cost Effectiveness | It can lead to cost reduction by reducing unnecessary maintenance tasks and optimizing resource allocation. | It takes into account the cost of preventive maintenance, risk, and potential equipment failure costs and unplanned downtime. |
| Equipment Monitoring | Constantly monitors the operation and condition of equipment to detect anomalies and deviations from normal working conditions. | Regular inspections and basic monitoring are conducted to ensure equipment operates within acceptable parameters. |
| Service Flexibility | Provides flexibility in scheduling maintenance tasks based on real-time equipment condition and prioritizing critical assets. | Based on mandatory regular equipment maintenance tasks. |
What indicators can be used for predictive maintenance?
Here are several examples:
- Vibration analysis, which helps detect imbalance, wear, defects in parts and components.
- Acoustic analysis that focuses on preventive measures to prevent lubrication material deficiency.
- Ultrasonic analysis used for electrical equipment and predicts failures better than vibration analysis.
- Infrared analysis, which is used when temperature is a good indicator of potential issues, and it is applied to detect cooling-related problems, airflow issues, and even motor overload.
How is Predictive Maintenance implemented?
PdM includes:
- Key performance indicators and allowable limits for those indicators.
- Sensors that collect data and transmit it for analysis.
- Software for processing and visualizing the information.
- Planning and execution of equipment maintenance and repair tasks.
PdM example.
In the field of processing and food production, refrigeration equipment is of paramount importance, as its failure can result in financial and reputational losses. To prevent equipment breakdown, sensors are installed to analyze the temperature and vibration of equipment parts and components. Any changes in these indicators serve as a signal of a problem before a breakdown occurs.
Predictive Maintenance has some drawbacks, such as costliness and technical complexity, which are offset by optimizing equipment repair costs and reducing forced and unplanned downtime.
An example of a data collection system for equipment created by Epol Soft can be found at the provided link.