5 Things You Miss Out On When You Opt Out Of Predictive Maintainence

The utilization of data analysis techniques to detect abnormalities and irregularities in equipment defines what is predictive maintenance. It is done so that maintenance can be done on equipment just before it fails.

The detections are predicted by using data. The data is collected from the equipment through various sensors. Both historical data and real-time data are used for predictions.

Predictive Maintenance

Predictive maintenance is a very essential technique. Here are 5 disadvantages you would be at if you don’t opt for predictive maintenance.

Increase In Machine Failures & Maintenance Costs

Predictive maintenance is a constant maintenance strategy. Systematic and constant maintenance of the equipment informs you about the conditions of the equipment and its parts.

The predictive maintenance helps to reduce the chances of unexpected and sudden failures of the equipment. This will prompt you to carry out the necessary repairs ahead of time so that the equipment operates properly.

Understandably, if you do not opt for predictive maintenance, the possibilities of your equipment experiencing unforeseen and catastrophic failures increase. Since the damages are unforeseen, you would not be prepared for the repairs immediately.

With predictive maintenance, your devices are monitored constantly for anomalies. If any abnormalities are found, you can carry out the repairs instantly. You can perform the maintenance at a low cost and with little manpower.

However, without predictive maintenance, the likelihood of a big and catastrophic failure increases. Thus, you would be required to carry out the maintenance at a higher cost now. In addition, the manpower demand would also increase.

Increase In The Equipment Downtime & Decrease In Production

Equipment downtime

Equipment downtime refers to the amount of time the equipment is not operational. It is wise to try to keep the equipment downtime to its minimum.

Predictive maintenance helps you anticipate the repairs required in your equipment. When you perform the maintenance before your hardware fails, you help keep the equipment not operating for the lowest possible time. 

This aids you in reducing your device’s downtime. A low downtime results in lesser halts in your equipment’s operations. Fewer halts in your machines help you to not only save your time but also in maintaining your schedule.

As the chances of sudden breakdowns of your machinery increase in the absence of predictive maintenance, the downtime of equipment also increases. This leads to longer stoppages of operations.

In big plants where time is of the essence, halts of long duration can cause massive losses. Stoppages also lead to a waste of your time as well as the manpower hired.

Predictive maintenance helps keep your machinery operating smoothly. It constantly monitors every part of your equipment and helps them stay in their best shapes.

Proper functioning machinery leads to constant production. Fewer and short stoppages also guarantee an increase in yields. 

If you do not employ predictive maintenance, the stoppages become longer. Hence, a decrease in production is expected. Constant failures of your machines and their parts are also a possibility affecting your production.

Increase In Stock Parts & Decrease In Lifetime Of Parts

Predictive maintenance informs you about the repairs in your equipment beforehand. This knowledge helps you to schedule the repairs, arrange the required parts, and gather the manpower well in advance. Thus, this strategy ensures a reduction in both repair time and costs.

The expenses caused by stocking the spare parts can be reduced. Knowledge of repairs in advance gives you ample time to order the required parts. This takes away the need for stocking spare parts and saves you the stocking costs.

When you stock the spare parts without the idea of when they can be used, it costs you a lot since the stocks also need to be maintained. You need bigger storage spaces as well. Predictive maintenance solves these issues for you.

Prevention of failures, as well as detection of anomalies and damages in the equipment, provides you a great advantage. It increases the service lives of equipment and thus the plants.

A regular predictive maintenance schedule helps diagnose the problems in your equipment. Upon solving them, your machine’s lifetime isn’t affected. However, without constant monitoring, chances of failure of your machines increase resulting in a decrease in the lifetime of the equipment.

Reduction In The Safety Of Operators

Predictive maintenance warns you about the repairs and maintenance required in your machinery. The anomalies detected in your equipment may cause a destructive failure or may cause it to malfunction.

When a machine malfunctions, it may cause harm to the operator who is operating it. This can result in an accident leading to injury. With predictive maintenance, you take care of the breakdowns beforehand and hence you prioritize your worker’s safety.

Decrease In Overall Profits

The profits of a plant can be affected by several factors. Production, the functioning of machinery, efficient use of time, and proper use of manpower are some of the factors.

Predictive maintenance directly affects the profits. With constant testing of the equipment, predictive maintenance ensures the equipment is in the best shape and is operating smoothly. Hence, production will be increased.

With repairs and maintenance scheduled, you utilize your time efficiently. You carry out the repairs on time, which leads to lower downtime of the equipment. So the operations of the machinery are back on track very soon. This doesn’t halt the progress of the plant.

With big and catastrophic failures out of the way, you don’t need to worry about them. You can then focus more on using your manpower to increase your profits.

However, when you opt out of predictive maintenance, your equipment downtime increases, and your production reduces. In addition, waste of time, resources, and manpower also take place.

Role Of OEE In Predictive Maintenance

OEE stands for overall equipment effectiveness. It is a key metric that measures an equipment’s overall productivity. Upon calculating the OEE of equipment or a piece of it, predictive maintenance can be scheduled.

Predictive maintenance then can be utilized for the optimization of the production processes. It can be also be used to carry out the required repairs and replacement of parts of the equipment.

Overall Equipment Effectiveness depends on three factors, availability, performance, and quality. Availability gives a measure of how frequently does the equipment function. The performance gives a measure of production. Quality gives the measure of defects in the production.

OEE can then be obtained by calculating the product of availability, performance, and quality. OEE method of predicting maintenance helps save companies time and capital.

In Conclusion

Predictive maintenance is an essential strategy for companies to optimize production, save capital and utilize time and manpower efficiently. Not opting for it puts you at a significant disadvantage.

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