Predictive maintenance is a strategy that uses indicators to prepare for future problems, while preventive maintenance involves regular, scheduled service. Predictive maintenance involves observation and assessments while equipment is operating normally, while preventive maintenance may be possible while equipment is operating. Predictive maintenance is based on real signals demonstrated by a single specific piece of equipment and involves comparing statistics for indications of an impending problem.
Maintenance costs are one of the biggest factors affecting a plant’s budget. Attempts to reduce these costs have led to the development of several maintenance strategies. Predictive maintenance is a defect inspection strategy that uses indicators to prepare for future problems.
One of the major mistakes made with predictive maintenance is that it is often confused with preventive maintenance, which consists of pre-planned routine measures used to prevent major problems. To better understand predictive maintenance, it’s best to contrast it with preventive maintenance, which is often a more widely recognized term.
Preventive maintenance involves regular, scheduled service. For example, a machine may be shut down every month for fluid replacement and refilling. Then, every six months, it can be shut down so its belts can be replaced. This is done in the hope that major problems associated with fluids and belts will not arise.
Predictive maintenance, by contrast, generally involves observation. You note indicators that may signal bigger problems. For example, a car may be checked regularly. If an abnormal fluid leak or moisture buildup is found, these act as signs that bigger problems could be occurring.
Another important difference between these two maintenance strategies is that preventive maintenance may be possible while an equipment is operating. However, in most cases, the equipment needs to be turned off for a period. Predictive maintenance almost always involves assessments that are performed while the equipment is operating normally. It will generally make inspection futile or inaccurate if a machine is evaluated for defects while it is shut down or its capacity is reduced.
Predictive maintenance is not based on hunches and hunches. It is not based on industry statistics, such as those that state that equipment must have specific service at specified intervals. Predictive maintenance is based on real signals demonstrated by a single specific piece of equipment.
This may include comparing statistics for indications of an impending problem. It is commonly known that one of the most costly mistakes made in industry is the failure to record and analyze data such as equipment performance and heat distribution. Figures that represent optimally functioning equipment are very good indicators against drastically different figures. If a cutter cuts 30,000 boxes every month for a year and then suddenly can only cut 20,000, that should be taken as a sign.
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