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Predictive Maintenance

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What are the key benefits of predictive maintenance? – How to improve reliability and cut costs at the same time.

Think of Predictive maintenance and condition-based maintenance as health checks for your machinery, much like a doctor’s checkup for a patient. When you go for a health check, the doctor uses various tests, from simple to complex, to assess your condition.

They may listen to your heartbeat, take your temperature, or perform an ECG to evaluate your heart’s health. If something is wrong, they recommend further tests and proactive measures to improve your health.

For machinery, predictive maintenance and condition-based maintenance work in a similar way. These strategies allow you to detect potential issues early and take proactive actions to prevent costly downtime.

In the UK, the term “Condition-Based Maintenance” is more commonly used, while in the US, you’ll often hear “Predictive Maintenance.” However, both terms refer to the same approach: performing maintenance based on the observed or inferred condition of an asset, rather than following a fixed schedule.

How Does it Work?

The essence of both strategies lies in assessing the “health” of your machinery. Instead of waiting for a scheduled time maintenance is carried out when the asset shows signs of wear or impending failure. This is where condition monitoring comes in. Regular monitoring and assessments, such as vibration analysis or thermography, help determine the condition of your equipment, allowing you to plan maintenance before a failure occurs.

Other Maintenance Strategies:

  • Run-to-Failure: Repairing or replacing equipment after it has stopped functioning.
  • Preventative Maintenance: Conducting maintenance based on a set time or usage schedule.
  • Functional Testing: Used to detect hidden failures with significant safety risks.
  • Proactive Maintenance: Redesigning assets to eliminate the need for maintenance or reduce the risks of failure.

Selecting the right strategy for your assets is critical. Pragmatic can assist with this process, offering expert advice tailored to your needs.

Understanding Condition-Based and Predictive Maintenance

Condition-based maintenance means making maintenance decisions based on the actual condition of the asset and identifying faults that could worsen over time. Predictive maintenance goes further by using condition monitoring data to predict future performance or potential failure, helping you avoid costly breakdowns.

What is Condition Monitoring?

Condition monitoring refers to the various technologies and methods used to assess the condition of machinery. This includes techniques like:

  • Vibration monitoring

  • Thermography

  • Oil analysis

  • Ultrasonic inspection

  • Motor current signature analysis

Even simple visual checks, such as regularly measuring tyre depth on a vehicle, qualify as condition monitoring. Using the data collected from these methods, you can apply condition-based or predictive maintenance to keep your equipment running efficiently.

Why Choose Predictive Maintenance?

Predictive and condition-based maintenance both aim to optimise the performance and reliability of your assets. Don’t be misled by claims that artificial intelligence is required to make accurate predictions—modern condition monitoring tools and methods are more than capable.

At Pragmatic Maintenance and Reliability, we specialise in setting up and managing predictive maintenance programs that fit your needs. We offer:

  • Fully Outsourced Programs: We handle data collection and analysis, providing you with a detailed health report and actionable recommendations.
  • Turnkey Solutions: We set up and train your team, handing over a fully functioning predictive maintenance program.
  • Mixed Services: You collect the data, and our experts perform the analysis, delivering comprehensive health reports with actionable insights.
  • Automated Monitoring Systems: We implement automated systems that send data to the cloud or an on-site server, alerting you to potential issues before they escalate.

For businesses that rely on high-performing machinery, predictive maintenance is a game-changer. Contact Us today to discover how our solutions can help you reduce downtime and extend the life of your equipment.