![]() The specific implementation of the strategy often needs to be adapted over time to remain effective. ![]() Preventive maintenance also typically requires active and ongoing review of maintenance schedules and the effectiveness of the approach. Most businesses, for example, will adopt SMART goals or aim to improve a specific KPI. The benefits of the strategy can also vary significantly depending on how it is implemented. The technician handling the check has to be paid or redirected from other work, and the machine will be out of commission during the inspection, potentially reducing site productivity. Machines need to be properly shut down, then locked and tagged out to be safely inspected. Parts that must be disassembled to be inspected may not be put back correctly, potentially causing damage or reducing machine performance.Įven in cases when checks don’t cause damage, they still cost time and money. Too much preventative maintenance can expose sensitive components to dust and other airborne particulates. Some maintenance checks can also put a machine at risk of damage. A preventive approach wouldn’t be able to prevent downtime in this case. For example, issues can easily arise and cause machine failure in between maintenance checks. The strategy, while widely adopted, is not perfect. Once a baseline of machine performance is established, the predictive system can alert site maintenance staff when a machine is performing unusually or about to fail, helping to further reduce downtime and maintenance costs. This approach uses IoT-based performance monitoring and AI algorithms to predict machine health based on current operational parameters - like heat, vibration, timing and pressure. ![]() Preventive maintenance also creates a good foundation for cutting-edge maintenance techniques, like predictive maintenance. One 2017 study found that 60% of best-in-class operators used the approach, and that, on average, they saw an 11% decrease in year-on-year maintenance cost and a 9% decrease in year-on-year downtime. Research on the approach has demonstrated that preventive maintenance can significantly extend the lifespan of manufacturing equipment and decrease maintenance costs over time An industrial press, for example, will need technicians to regularly inspect tool wear, adjust the mechanical assembly for tightness and add lubricant as needed. The exact repairs and checks needed will vary from machine to machine. On a regular basis, technicians will conduct repairs, component replacements and maintenance checks that help to ensure the machine is kept in good working order and that issues are caught early. With this approach, a manufacturer follows a maintenance schedule - either their own or one developed by an OEM. Preventive maintenance has long been considered the gold standard for manufacturing maintenance strategies, and is one of the most popular maintenance strategies, favored by around 80% of all maintenance personnel according to a 2018 Plant Engineering survey. Knowing the differences between the two will help a manufacturer determine which is best for their business. The two strategies differ significantly in terms of investment, time needed and potential results. Two of the most common maintenance strategies are corrective and preventive maintenance. The right approach can significantly extend the lifespan of a machine while reducing downtime, preventing damage and cut down on the need for repairs. For any manufacturer, effective maintenance is essential.
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