Predictive & Proactive Maintenance: What is their importance in Industries?

What is Proactive Maintenance?

Proactive maintenance is a kind of process or strategy that is done to recover the root causes of failure and to prevent breakdowns caused by radical/critical machinery conditions. 

Purpose - The purpose of Proactive maintenance is to find machinery failures that are expected and to get rid of it before the fault occurs.

Benefits of Proactive Maintenance-

·  Reduction in unplanned outages and affiliated costs

·  Helps organizations in prevention of under maintaining assets

·  Offers reliability, Costs Balancing, up time and asset health.

·  Reduction in  energy consumptions

·  Reduce equipment failure and risks by operating faulty equipment

·  Saves time and money as repairs on larger scales are reduced

·  Improvement in Service with less downtime and efficiency in machine.

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WORKFLOW

 More Streamlined Reports

Working

1.  Focusing on failure modes:  Prioritization of plant systems and failure modes with impact on capability and availability.

2.  Buy-in Receiving from Management:  Investment of maintenance resources and technologies with Business Decisions.

3.  Adopting Technologies: Selection of available maintenance technologies with wireless competency.

4.  Enhancement in employee skill set: Increase in the core competency of the maintenance team.

Predictive& Proactive maintenance both plays important and different roles in industries, since maintenance is the key aspect of manufacturing plants. Let us first learn predictive maintenance:

 

What Is Predictive Maintenance?

Predictive maintenance is a kind of proactive maintenance technique that applies to  predict when the equipment tends to fail. This is so that maintenance task or recovery can be performed  just before that happens.

Purpose: The purpose of this Predictive maintenance is to evaluate the condition of equipment on the basis of data evaluation through the use of various condition monitoring sensors and techniques.

Benefits:

·   Reduction in  unexpected breakdowns and maximizing asset up-time which improves reliability

·  Reduce operational costs by performing maintenance only when required thus reduction   in excessive or unwanted maintenance

·  Improves bottom line by maximizing production hours

·  Verification of repairs which is required  to correct inadequate or incomplete repairs.

Working:

Predictive Maintenance depends upon condition-monitoring equipment to evaluate the performance of assets in real-time. It provides accurate tool for collecting and analyzing assets Information.

Condition-monitoring  is needed because although maintenance personnel observe assets through physical inspections of equipment but  there has been a critical drawback in that procedure – the most wear and tear happens in the machines for which you need to perform accurate inspection of what is happening inside to take them out without any interruption in productivity. Predictive & Proactive maintenance needs condition monitoring to know the status of equipments.

Conditional Monitoring  Sensors measure parameters like vibration, noise, temperature, pressure, etc . Beyond above parameters they are also used to measure electrical resistance and corrosion.

·        Used to make predictions about unknown future events that can be occurred.

·        Evaluate information of IT and business processes with management to make future predictions.

·        It is helpful in interpretation of large data in business organization

·        Provide options to create predictive models for future.

·        Helps in decision making based on Prediction models.