A Guide to Predictive Maintenance

Predictive maintenance is a proactive approach that monitors the asset condition & its performance in real-time, to predict failures before they occur. It uses a combination of wireless Industrial IoT sensors, and data analytics, to identify the warning signs of future failures.

Predictive Maintenance Definition

Predictive maintenance is a technique that involves continuously monitoring the condition of a machine, in order to analyze parameters, such as vibration or temperature, for obtaining meaningful insights about its health and performance. This method of permanent monitoring offers the opportunity to obtain real-time data about the machine’s condition and identify faults that may lead to failures. This helps plan & undertake maintenance activities to prevent unplanned downtime.

To perform predictive maintenance, condition monitoring sensors are installed on the machines to monitor and collect data. This data is then analyzed to identify faults and predict failures. The sensors collect and analyze complex data about the machine health & performance, to predict when it will fail. The Predictive Maintenance Solution then identifies the issues developing in machine components at an early stage, and prevents unplanned downtime. It notifies maintenance & reliability professionals when assets start to show initial signs of failure, thereby giving enough time for engineers & technicians to schedule repairs. It offers the potential to maximize the machine uptime, by predicting faults and allowing enough time to schedule repairs, without affecting production.

Advantages of predictive maintenance

Predictive maintenance provides many advantages to manufacturers and operators:
  • It offers a way for technicians and engineers to predict when an asset will fail. This prediction and notification give enough time for them to schedule repairs, thus reducing unplanned downtime in the future.
  • Data analytics also provide organizations with the opportunity to produce better products at a faster rate without sacrificing quality or consistency. By collecting and analyzing machine health and performance data before an asset fails, predictions can be made about which assets need attention. Furthermore, predictive maintenance helps detect developing issues before they become major problems.
  • Predicting failures in advance offers maintenance & reliability professionals to allocate resources prudently, thus saving significant time and cost involved in the maintenance activities. This is mainly because energy & funds spent only on necessary maintenance activities and not on routine inspections & replacements.
  • Predictive maintenance facilitates timely repairs of components, thereby allowing manufacturers to maintain machines & equipment sets in the optimal condition.
  • Predictive maintenance also allows manufacturers to maintain customer demand by meeting deadlines and providing consistent service delivery. Organizations that adopt predictive maintenance programs usually experience improved customer satisfaction and increased profitability.

Disadvantages of Predictive Maintenance

Predictive maintenance, like any other practice, is not without its limitations. Some of them are detailed below:
  • Implementing a predictive maintenance solution is a costly affair, and a significant component of it can be attributed to the cost of installing necessary technology.
  • Change management and training the staff is another challenge as the employees will have to adopt newer technologies and practices over traditional methods.
  • Although predictive maintenance offers companies the potential to produce better products at a faster rate without sacrificing quality or consistency, it will only prove fruitful when implemented appropriately.
  • Not all industrial assets may incur costly failures. For those assets which cause minimal downtime or incur lesser maintenance cost, it may be beneficial to adopt a preventative maintenance approach rather than a predictive one.
The advantages of predictive maintenance are clear and include cost savings by preventing unplanned downtime in the future. While Predictive Maintenance has some limitations, they can be overcome by examining the company's needs and capabilities before implementing maintenance measures.

Goals of Predictive Maintenance

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  • The main goal of Predictive Maintenance is to reduce unexpected failures and unplanned downtime.
  • Predictive maintenance can help prevent costly failures and increase productivity of the overall manufacturing operations, enabling to maintain consistent manufacturing/production.
  • By reducing the need for unexpected downtime, predictive maintenance can help save production costs and decrease customer's lead time.

How Much Does Predictive Maintenance Cost?

Predictive maintenance is not a new concept and has been around since the 1970s. The idea of predicting when an asset will fail and then taking preventive measures, is a very old one.

On average, predictive maintenance systems cost about $2 per machine hour. But this is just for the equipment and software necessary to get started. It is essential to note that companies may need to pay someone who knows how to program the system and set up the sensors. Alternatively, most of the manufacturing organizations partner with Predictive Maintenance solution providers for implementing a PdM regime as well as to train their employees.

Many companies also use predictive maintenance for more than just machinery. It can also be used for other assets like computer networks, HVAC systems, and even water pipes! You may not use the data from all of these assets already, but it's worth considering if you're looking into making your business more efficient.

Return On Investment

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The process of predictive maintenance is implemented to increase the reliability and quality of production, reduce downtime and improve uptime. Predictive maintenance has a direct and positive impact on all three areas:
  • Quality: It reduces defects and machine downtime, which can result in increased productivity.
  • Productivity: Predictive maintenance helps production operators achieve higher outputs because it minimizes downtime.
  • Uptime: Predictive maintenance helps to keep the machine in optimal condition, thereby increasing uptime (time that machine is operational). Increased uptime results in improved equipment utilization rate, less inventory carrying costs and increased customer satisfaction with products/services provided by the organization.

According to Deloitte, predictive maintenance results in

5-10% Material Savings


5-10% reduction in overall maintenance costs

10-20% increase in equipment uptime & availability

How can Nanoprecise Sci Corp Help you?

Nanoprecise Sci Corp is an automated AI-based predictive maintenance solution provider that facilitates early detection of even small changes in machine operations well before they impact production or cause downtime. Nanoprecise specializes in the implementation of Artificial Intelligence and Industrial IoT technology for predictive asset maintenance and condition monitoring. The AI-based solution offers real-time predictive information about the genuine health and performance of industrial assets.

Nanoprecise helps customers across the world to increase production and reduce unplanned downtime while allowing maintenance teams to focus on value added activities rather than routine data gathering and analysis.

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We use an agile service approach, where we analyze six available data points from the equipment sets, to offer actionable insights that significantly enhance the maintenance of critical assets and facilitates effective failure management. We have helped countless asset-intensive firms reduce machine downtime, improve performance and dependability while cutting maintenance costs by focusing the manufacturers’ expert-level personnel on true value-add activities.

Customised to your Industry Needs

Industries


Reducing Downtime in Metal Industry

Our IoT driven Predictive maintenance solution helps to reduce downtime, monitor, collect exchange and analyze data from machines to enhance manufacturing processes of the metal industry.

Scaling Iot in Manufacturing Industry

Machine failure in the mines? No worries.

Our solutions can add immense value to your entire mining supply chain by harnessing the power of Industry 4.0. The asset performance will be optimized, costs and machine downtime can be reduced leading to a boost in ROI.

Predictive Maintenance in Mining Sector

No more unplanned downtime in Cement Industry

Our Industry 4.0 digital solutions can help you tackle the challenges in cement production such as large energy consumption, high costs and complex processes.

Our advanced analytics can simplify complexities and help in real-time decisionmaking. Equipment lifespan and reliability will amplify due to our condition monitoring system.

Predictive Maintenance in Cement Plant

Protect your assets with Zone Approved Solution

Our digitization solutions in industrial equipment maintenance can help oil and gas companies streamline maintenance. Our predictive analytics and conditional data monitoring help anticipate failures, reducing unplanned maintenance and unscheduled downtime.

Predictive Maintenance in Oil & Gas Plant

No more Downtime, Keep your Machines Running in Chemical Plants

Our AI driven analytics can propel your chemical business to new heights of reliability by optimizing asset longevity and impacting top-line growth through proactive identification of upcoming machine failures. IoT driven asset maintenance solutions can provide immense flexibility and agility to production.

Predictive Maintenance in Chemical Plant

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    Frequently Asked Questions

    Predictive maintenance is a maintenance strategy that uses physics and mathematical computations to assess the health of machines and equipment sets. It allows to detect faults in advance and predict potential failures in machines. It is aimed at reducing unplanned downtime, optimizing maintenance resources, providing improved operational visibility and increasing productivity.

    Predictive maintenance allows to maximize the uptime of industrial assets and helps maintenance & reliability professionals to optimize maintenance resources by predicting failures in advance. It not only facilitates reduced downtime but also enables improved operational efficiency for organizations.

    Some of the notable advantages of predictive maintenance include reduced unplanned downtime, increased productivity, complete visibility of manufacturing & production operations, reduced maintenance costs, and improved worker safety.

    Predictive maintenance helps to pinpoint faults in advance to predict failures, thereby allowing the maintenance and reliability professionals to plan maintenance activities at a cost-effective time. According to Deloitte, predictive maintenance can on average, increase the productivity by 25%, reduce breakdowns by 70% and lower the maintenance costs by approximately 25%.

    The benefit of implementing predictive maintenance is reaped by various industries including Cement, Chemicals, Energy, Metals, Mining, Mobility, Oil & Gas, Power, Pharmaceutical, and Infrastructure & Facilities among others.