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WK 8 Report Draft

Predictive maintenance tools fall into three categories: sensors that generate data; analytics and monitoring tools that analyze sensor data; and scheduling tools that coordinate maintenance. Effective predictive maintenance requires collecting baseline equipment data, using condition monitoring sensors and technologies like CMMS, and leveraging IoT devices. CMMS systems help manage maintenance activities and integrate areas like inventory, work orders, and preventative maintenance for cost savings.

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21 views4 pages

WK 8 Report Draft

Predictive maintenance tools fall into three categories: sensors that generate data; analytics and monitoring tools that analyze sensor data; and scheduling tools that coordinate maintenance. Effective predictive maintenance requires collecting baseline equipment data, using condition monitoring sensors and technologies like CMMS, and leveraging IoT devices. CMMS systems help manage maintenance activities and integrate areas like inventory, work orders, and preventative maintenance for cost savings.

Uploaded by

alinsasaguinjoy
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(Dilmegani, 2023)TOPIC: Maintenance Tools (Tools Technology) and Strategy

EXPECTED COMPETENCIES

After completing this module you will be able to:


• Understand the three classes of predictive maintenance tools and their importance;and
• Discuss the importance of TPM and CMMS.
•
According to Dilmegani (2023), with an increasing volume of industrial activities manufacturing are
supported by robots, artificial intelligence (AI) and other modern technologies that enable organizations to get
the most from every effort.
With this growth and change, comes an evolution in the tools that are designed to support manufacturing.
Some of the biggest changes have been methods for keeping different manufacturing components functioning,
and functioning well, for longer periods of time.

Predictive maintenance is one such improvement - to intercept possible failures and to fix them to avoid
downtime that would otherwise be caused by failure. This then results in less time spent out of work, less money
spent on repairs, and less human effort in managing all these assorted processes.

In fact, according to Maiti (2021), 91% of manufacturers who set up a predictive maintenance program saw a
reduction in maintenance time. As well as there is a 9% increase in equipment uptime and a 20% expansion in
the life cycle of old assets.
Predictive Maintenance (PdM) refers to the use of data-driven, proactive maintenance methods
that analyze the condition of equipment and help to predict when maintenance should be
performed.

It is one type of maintenance that checks the condition and performance of equipment during normal running
operations. By doing so, maintenance personnel can identify possible defects and fix them before they result
in a failure.

Three (3) classes of predictive maintenance tools

There are 1000+ tools enabling predictive maintenance in 3 categories. Tools in separate categories complement
one another:

• Sensors generate data


• Analytics & monitoring tools help clean and analyze that data
• Scheduling tools coordinate teams in the field guiding them to carry out maintenance activities

IoT Sensors

Sensors have always been an important part of any maintenance plan because they allow us to monitor slight changes
and adjust accordingly to prevent small issues from evolving into major problems. Having multiple different sensors
monitoring different metrics can be key to getting a better understanding of your processes and preventing early failures
and the resulting downtime they cause.

Oil & lubricant sensors


Oil analysis can determine many factors of your machine performance. Actual oil viscosity versus expected viscosity can
show how your machine is preventing oxidation, dilution, moisture, etc. Metal shards in the oil can alert technicians to
parts grinding that might slow or break a machine. Sensors that calculate fluid dynamics might help expose a leak or faulty
connector.

Monitoring and industrial analytics tools


Industrial analytics is often considered to be an integral part of the ‘fourth industrial revolution’, which is characterized
by the convergence between traditional industrial practices and modern IT improvements. These advances include data
analytics and their related interpretation via machine learning, and also advances in connectivity through IoT.

NOTES:

What this means practically speaking is that a greater number of decisions and actions are starting to become
based much more deeply on measurable data that can be acted upon quickly.
Schedulers

Software leaders like IBM, SAP and SAS create full range technology suites. These suites combine
machine learning and the sensor data to compile maintenance plans.

Remember that predictive maintenance is about monitoring equipment and acting only when necessary.
Technology programs designed for industry are honing in on when, precisely, action is required.

NOTES:

Modern versions of a traditional solution automate maintenance analysis, reducing the work previously done
by a person. This frees up that person to focus on reviewing the changes and results. By letting a scheduling tool
handle the analysis, it greatly reduces the time and effort needed to consider all factors. However, it's important to
remember that some human knowledge and judgment are still valuable, especially in cases where a computer might
not recognize certain priorities.

Predictive Maintenance process

Predictive maintenance involves several key steps:

1. Establish Baselines: Start by monitoring the conditional baselines of your assets and collecting data
before installing sensors. This provides a reference point to compare against when abnormalities
occur.

2. Use Condition-Monitoring Technology: Pair your predictive maintenance program with the right
technology, such as a Computerized Maintenance Management System (CMMS) and IoT-enabled
devices. These tools help collect and manage the necessary data effectively.

3. Leverage IoT: IoT devices play a crucial role by collecting data from condition-monitoring sensors and
connecting it to a maintenance management system. This data is essential for predictive maintenance.

“To effectively collect the right data, predictive maintenance programs have to be paired with the
right condition-monitoring technology. In particular, a CMMS and multiple IoT-enabled devices.”

Computerized Maintenance Management Systems (CMMS) are vital in this process:


• What Is CMMS: CMMS is a computerized system that helps manage maintenance activities efficiently
using technology.
• Core Function: It's centered around a database that organizes information about assets, equipment,
materials, and resources needed for maintenance.
• Integrated System: CMMS integrates various areas of maintenance, such as inventory management,
preventive maintenance, and work order tracking, making it cost-effective for organizations of different
sizes.
Predictive maintenance and CMMS can lead to significant cost savings:

• Costs of Neglect: Failing to maintain equipment properly can result in high costs, including
breakdowns, unproductive downtime, and lost business.

• Historical Methods: Older, manual maintenance management methods were inefficient and
inconsistent, while CMMS offers a more reliable and comprehensive tracking system.

WHY there is a need for CMMS today?

• Safety: To prevent accidents and fires caused by poor maintenance.

• ISO Compliance: Many companies implement ISO standards, which require effective maintenance
systems.

• Productivity: CMMS is essential for Total Productive Maintenance (TPM) programs and Total Quality
Management (TQM) initiatives to gain a competitive edge.

• Cost Efficiency: Effective maintenance management leads to savings in time and costs and improved
productivity.

The impacts of CMMS include:

• Reduced Downtime: Regular preventive maintenance reduces equipment downtime.

• Extended Equipment Life: Maintenance helps increase the lifespan of equipment.

• Improved Craft Productivity: Efficient maintenance processes enhance the productivity of


maintenance teams.

• Lower Inventory: Proper maintenance reduces the need for excessive inventory.

• Less Emergency Maintenance: Well-planned maintenance reduces the need for emergency repairs.

• Historical Records: CMMS provides historical data for maintenance planning and budgeting.

• Customized Reports: CMMS generates maintenance reports in user-friendly formats.

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