Allow convenient scheduling of corrective maintenance and prevent unexpected equipment failures.
Predictive maintenance (PdM) techniques help determine the condition of operating equipment to predict when maintenance should be performed. By monitoring and acting prior to failure, cost savings are achieved because tasks are neither in wasted preventive activity, nor as response to failure, but just before necessary.
The main promise of predictive maintenance is to allow convenient scheduling of corrective maintenance, and to prevent unexpected equipment failures. With knowledge about which equipment will need maintenance, work can be better scheduled (spare parts, downtime, personnel, materials, etc.). Increases in plant availability, equipment lifetime, and plant safety are also valuable to all production operations. Costs can be impacted with better utilization of MRO items and plant skilled trades overtime reduction.
Predictive maintenance evaluates the condition of equipment by performing periodic (offline) or continuous (online) equipment condition monitoring. The ultimate goal of the approach is to perform maintenance at a scheduled point in time when the maintenance activity is most cost-effective and before the equipment loses performance. The \”predictive\” component of predictive maintenance uses principles of statistical process control to predict the future failure of the equipment.
Most predictive inspections are performed while equipment is in service, thereby minimizing disruption of normal system operations. Adoption of PdM can result in substantial cost savings and higher system reliability.
Reliability-centered maintenance (RCM) emphasizes the use of predictive maintenance techniques in addition to traditional preventive measures. When properly implemented, RCM provides companies with a tool for achieving lowest asset net present costs (NPC) for a given level of performance and risk.
Technologies for use in predictive maintenance are many nondestructive testing technologies such as infrared, acoustic (discharge and airborne ultrasonic), vibration analysis, sound level measurements, oil analysis, and other specific online tests.
Use of the PdM data in a computerized maintenance management system (CMMS) allows for equipment maintenance planning and work order execution. Unless somewhat automated, a PdM program will be unable to be sustained.