PREDICTIVE MAINTENANCE AND CONDITION MONITORING
PPS provides plant operators with the resources to implement and maintain a condition-based predictive maintenance program. As technology advances, so will our service offering. As each business faces unique operational challenges, its maintenance requirements are unique as well. PPS develops predictive maintenance solutions ranging from client-specific proprietary programs to complete PPS-supplied solutions based upon Reliability Centered Maintenance Fundamentals and Machine Learning (A.I.).
WHAT IS PREDICTIVE MAINTENANCE AND CONDITION MONITORING
Predictive Maintenance and Condition Monitoring is the process of observing the operation of equipment. Continuous monitoring systems watch equipment to prevent catastrophic failure during operations. However, when the condition monitoring system acts, the equipment fails, requiring an appropriate response.
Typically, the action of the condition monitoring system prevents additional failures. On its own, the system does not provide any further indication or analysis of the equipment, nevertheless, to predict when or where the next failure will occur. Unknown equipment failure puts maintenance departments in a scramble to order replacement parts, schedule the personnel to make the repairs, or they could prevent the failure from occurring in the first place.
Unexpected equipment downtime is costly and leads to a reactive maintenance process to recover the equipment operations quickly. The purpose of predictive
maintenance is the ability to predict future equipment failure. The ability to predict the likelihood of future failure is invaluable. However, understanding the root cause is required to prevent equipment failure, and having reliable data to analyze leads to determining the root cause. Today’s environment of made-to-order components and manufacturers spread out worldwide, resulting in a lead time issue.
HOW DOES IT WORK
PPSs Nondestructive Testing, Condition Monitoring, and Predictive Maintenance System quantify plant equipment condition during regular operation, identifying current maintenance issues. Condition Monitoring System utilizes real-time sensor measurements and stops the equipment, preventing additional damage when appropriate. The system notifies maintenance personnel when it determines there is an ongoing issue that needs maintenance support.
The Predictive Maintenance System analyzes the collected data to predict future machine performance and provides forecasting using preventive maintenance statistics, reducing an unscheduled shutdown of facility operations.
Over time, eliminating failure modes improves preventive maintenance statistics resulting in cost reduction and increased equipment throughput. Predictive Maintenance and Condition Monitoring systems optimize equipment performance and are an investment in operational productivity, leading to several predictive maintenance advantages, including:
- Optimized equipment reliability
- Increased component operational life and availability
- Preemptive corrective actions
- Minimized unscheduled downtime
- Decreased costs for parts and labor
- Improved Safety
- Increased Morale
- Minimized energy and Power Consumption
- Reduced collateral damage to other equipment
- Optimized equipment reliability
- Reliable product quality
Predictive Maintenance and Condition Monitoring is the process of observing the operation of equipment. Continuous monitoring systems watch equipment to prevent catastrophic failure during operations. However, when the condition monitoring system acts, the equipment fails, requiring an appropriate response.
Typically, the action of the condition monitoring system prevents additional failures. On its own, the system does not provide any further indication or analysis of the equipment, nevertheless, to predict when or where the next failure will occur. Unknown equipment failure puts maintenance departments in a scramble to order replacement parts, schedule the personnel to make the repairs, or they could prevent the failure from occurring in the first place.
Unexpected equipment downtime is costly and leads to a reactive maintenance process to recover the equipment operations quickly. The purpose of predictive maintenance is the ability to predict future equipment failure. The ability to predict the likelihood of future failure is invaluable. However, understanding the root cause is required to prevent equipment failure, and having reliable data to analyze leads to determining the root cause. Today’s environment of made-to-order components and manufacturers spread out worldwide. This results in a lead time issue.
Results of Predictive Maintenance and Condition Monitoring Systems
Utilizing PPS predictive maintenance tools to identify the root cause of breakdowns using functional failure analysis (FMEA and FTA) results in the data needed to reduce unscheduled downtime. Providing a baseline to determine the best corrective maintenance action and, if appropriate, applying simulation capability to validate and optimize the solution. Predictive maintenance and Condition Monitoring systems work together to ensure the current and future optimal use of equipment.
HOW DOES IT WORK
PPSs Nondestructive Testing, Condition Monitoring, and Predictive Maintenance System quantify plant equipment condition during regular operation, identifying current maintenance issues. Condition Monitoring System utilizes real-time sensor measurements and stops the equipment, preventing additional damage when appropriate. The system notifies maintenance personnel when it determines there is an ongoing issue that needs maintenance support.
The Predictive Maintenance System analyzes the collected data to predict future machine performance and provides forecasting using preventive maintenance statistics, reducing an unscheduled shutdown of facility operations.
Over time, eliminating failure modes improves preventive maintenance statistics resulting in cost reduction and increased equipment throughput. Predictive Maintenance and Condition Monitoring systems optimize equipment performance and are an investment in operational productivity, leading to several predictive maintenance advantages, including:
- Optimized equipment reliability
- Increased component operational life and availability
- Preemptive corrective actions
- Minimized unscheduled downtime
- Decreased costs for parts and labor
- Improved Safety
- Increased Morale
- Minimized energy and Power Consumption
- Reduced collateral damage to other equipment
- Optimized equipment reliability
- Reliable product quality
U.S. Department of Energy:
Studies from the U.S. Department of Energy estimate that a Predictive Maintenance Program delivers 8% to 12% savings. Savings from an over-reactive maintenance approach is 30% to 40%.
Investments in a predictive maintenance program lead to the following results:
- Return on investment: 10X
- Reduction in maintenance costs: 25% to 30%
- Elimination of breakdowns: 70% to 75%
- Reduction in downtime: 35% to 45%
- Increase in production: 20% to 25%
- Results in 8% to 12% cost savings