Analyzing production data to predict problems before they occur and to identify patterns is predictive maintenance. Machine operators and factory managers had to repair machine parts regularly and create scheduled maintenance plans to avoid downtime, which ultimately wasted a lot of time, effort, and resources.
Thankfully, predictive maintenance has arisen to replace that, and here are a few reasons why manufacturers benefit from it.
Preventative vs Predictive
In the past, manufacturers relied on preventative maintenance to avoid downtime. It involved creating a scheduled maintenance plan that they guessed when it should be and visual inspections. It also had routine asset monitoring that gave objective and limited information on the system or machine’s condition.
So, manufacturers had to repair and maintain machines regularly. With predictive maintenance, technology gives them the advantage by lessening the amount of time and resources wasted thanks to proper usage of data.
How it Works
There are many base components needed for predictive maintenance to get carried out. Some of those things include predictive analysis, sensors, central data store, data communication, etc. Manufacturers have to make a blueprint for the connected system.
These are the manufacturing system along with the sensors, communication protocols, cloud, business systems, etc. and map out the parameters of failure for their machines to make it useful. So, it can let you know if you need more compression springs from Michigan without having to check it yourself.
Competitive Advantage
One of the best things about predictive maintenance is that it can give you an edge from your competitors. Predictive maintenance can give value to customers and strengthen company branding. It lets your products stand out from the competition. That way, manufacturers can provide continuously benefit in-market.
Improved Customer Satisfaction
Customers can get happier with the products that you offer them. You can send them automated alerts to let them know if a part should get replaced. It can also recommend timely services to keep them satisfied. Additionally, it can offer a better measure of predictability.
New Revenue Stream
Manufacturers can benefit financially from industrial predictive maintenance because they can offer analytics-driven services to their customers. Some of these services can include technician dispatch services before a part needs replacement, optimized maintenance schedules, and PdM dashboards.
That way, they can offer more digital services based on data to satisfy their customers. It allows manufacturers to get recurring revenue streams.
Increased Efficiency
One of the main reasons why manufacturers are talking about predictive maintenance is because it increases efficiency. Analytics-driven insights can improve OEE, which is overall equipment effectiveness. It will enable the root cause analysis of the system to find issues before failure.
It will also extend asset life and reduce unneeded maintenance.
Reduced Maintenance Time
While scheduled maintenance was popular before, it proved to create more downtime than it was meant to avoid. With predictive maintenance, it decreased the overall maintenance costs by as much as 15% to 10%.
Automatic reports for proactive repairs and strategic maintenance scheduling also reduced maintenance time by around 20-50%. That way, both the customer and the manufacturer save money and time.
Predictive maintenance has taken a shine on the manufacturing industry to replace preventative maintenance. All manufacturers should take advantage of it to enhance their business.