Slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Predictive maintenance and conditionbased monitoring. An introduction to predictive maintenance 2nd edition by r. Predictive maintenance pdm is the process of using asset operating conditions to predict when and how a failure will occur. Consider a situation where the predictive algorithms would trigger the creation of a maintenance work. Predictive maintenance is surely one of the most talkedabout topics in maintenance and asset management. Predictive maintenance industrial internet of things. Predictive maintenance part one of a predictive maintenance series predictive maintenance programs come in all shapes and sizes, depending on a facilitys size, equipment, regulations, and productivity goals. Predictive maintenance is the intelligent health monitoring of equipment to avoid future equipment failure. Condition based, diagnostic model, predictive maintenance, machinery, centrifugal pumps. Maintenance, although requiring the expenditure of significant amounts of energy, is usually required in order to keep or restore facilities at an acceptable operational standard 1. In contrast to preventive maintenance, which follows a set timeline. It monitors each assets condition to determine its fitness for continued operation and initiates repairs only when the machine itself starts crying for help.
I noticed that most of the answers actually revolved around listing conditionmonitoring techniques that are used as a part of conditionbased maintenance and, in extension, are an. This guide provides information on establishing an effective maintenance program to help prevent unexpected motor failures, costly downtime, and unnecessary maintenance costs. Predictive maintenance can reduce or even eliminate unplanned downtime by predicting when a machine needs checkups or when it may become faulty. By moving from a reactive state to a proactive state, an enterprise can drive truly differentiated. An introduction to predictive maintenance, second edition. Maintenance planning and parts procurement must be done in real time to make predictive. Predictive maintenance industrial internet of things iiot. An introduction to predictive maintenance plant engineering. Operational efficiency, equipment roi and safety considerations give rise to an industry need to ensure that the equipment is functional and utilized to its potential.
A game changer for manufacturing 4 predictive maintenance on the production line 5 predictive. Predictive maintenance evaluates the condition of equipment by performing periodic offline or continuous online equipment condition monitoring. Understanding and implementing predictive maintenance. Scheduled maintenance is based on hours by the book or fuel consumption. Predictive online monitoring of equipment in order to use importantexpensive parts to the limit of their serviceable life. Pdf an introduction to predictive maintenance second. Operational efficiency, equipment roi and safety considerations give rise to an industry need to ensure that.
The raw data is preprocessed to bring it to a form from which you can extract condition indicators. Reactive strategies operation until failure and preventive strategies are unable to minimise the total costs for downtime, maintenance and component exchange see fig. Integrate your predictive maintenance and services capabilities with sap enterprise solutions such as sap s4hana and thirdparty maintenance execution systems. Outlines some of the most common predictive maintenance methods explains how to determine the potential cost. It monitors each assets condition to determine its fitness for continued operation and initiates repairs only. Using predictive analytics to optimize asset maintenance in the utilities industry by working proactively to collect and distill digital information, transmission and distribution utilities can. Waiting until equipment fails before repairing or servicing it. Maintenance, although requiring the expenditure of significant.
The maintenance function is evolving from being afterthefact, to planned, to predictive. Modern industry is at a crossroads in todays world. Introduction to predictive maintenance the introduction to predictive maintenance is a threeday seminar designed to give workers an introduction to the methods, procedures, and philosophies used in predictive maintenance. Maintenance has evolved from the ageold ad hoc corrective or reactive maintenance cm to preventive maintenance pm and then to the presently popular predictive. Outlines some of the most common predictive maintenance. Combine sensor data with business information in your erp, customer relationship management crm, enterprise asset management eam, and augmented reality systems using sap. Using predictive analytics to optimize asset maintenance in the utilities industry by working proactively to collect and distill digital information, transmission and distribution utilities can enhance customer satisfaction, reduce total cost of ownership, optimize the field force and improve compliance.
We generally forget about the roof until it leaks on our computers, switchgear, tables. Predictive maintenance by electrical signature analysis to induction motors 505 in which taps was inserted to the gradual introduction of imbalance in power depending on the insertion of short. Predictive maintenance for effective asset management. Typical maintenance is based on a schedule, navarro says.
Predictive maintenance by electrical signature analysis to induction motors 505 in which taps was inserted to the gradual introduction of imbalance in power depending on the insertion of. In order to find out where companies currently stand. Predictive maintenance is the complement of preventive maintenance. Part one of a predictive maintenance series predictive. An introduction to predictive maintenance second edition. Using predictive analytics to optimize asset maintenance. The book provides practical knowledge about predictive maintenance engineering. Reliability centered maintenance rcm is a process used to determine the maintenance requirements of any physical asset in its operating context. Pdf predictive maintenance by electrical signature analysis.
Predictive maintenance pdm definition techniques that help determine the condition of inservice equipment in order to predict when maintenance should be performed primary goal. The old adage out of sight, out of mind is particularly true when it applies to lat roof maintenance. Management is driven to reduce costs and provide higher productivity. Consider a situation where the predictive algorithms would trigger the creation of a maintenance workorder in the companys cmms system, check the erp system for spares on hand, and automatically create a purchase request for any additional parts required. The ultimate goal of the approach is to perform maintenance at a scheduled point in time when the maintenance activity is most costeffective and before the equipment loses performance within a threshold.
The student will be introduced to the various techniques used to predict and. Pdf predictive maintenance by electrical signature. Understanding and implementing predictive maintenance excellence. Electric motor predictive and preventive maintenance guide electric motor failure could result in lost capacity as well as excessive repair and maintenance costs. Predictive maintenance the strategy that predicts when.
In this way, maintenance can be planned and there is an opportunity to change only those parts that are showing signs of deterioration or damage. Some of our clients have estimated that enhanced predictive maintenance could save them 20 percent or more on maintenance costs for key. Choose a subscriptionbased model based on the volume of devices and data storage. In contrast to preventive maintenance, which follows a set timeline, predictive maintenance schedules are determined by analytic algorithms and data from equipment sensors. Preventive and predictive maintenance is a maintenance system which very reliable to prevent some sudden troubles or breakdown that may happened on factorys toolsequipments. Instead, it relies on trending, comparative analysis orin the case of vibrationbased programssimplified signature analysis to maintain the operating condition of the plant. Predictive analytics encompasses a variety of techniques from statistics and data mining that analyze current and historical data to make.
This second edition of an introduction to predictive maintenance helps plant, process, maintenance and reliability managers and engineers to develop and implement a comprehensive maintenance management program, providing proven strategies for regularly monitoring critical process equipment and systems, predicting machine failures, and scheduling maintenance accordingly. Predictive maintenance techniques are designed to help determine the condition of inservice equipment in order to estimate when maintenance should be performed. A central database is at the core of a predictive maintenance platform. Predictive and preventive maintenance ced engineering.
Electric motor predictive and preventive maintenance guide. It helps plant, process, maintenance and reliability managers and engineers to develop and implement a comprehensive maintenance management program. The diagnostic capabilities of predictive maintenance technologies have increased in recent. Even in the case of regularly scheduled maintenance, the outcomes are suboptimal, as. An introduction to predictive maintenance 2nd edition. Predictive maintenance uses noninvasive techniques to monitor the pulse of a manufacturing plant. The contents of an introduction to predictive maintenance 1 impact of maintenance 2 financial.
This typically requires the use of software, which uses asset condition data gathered through hardware to create graphs and reports that managers can use to make informed. A simple practical framework for predictive maintenance pdmbased scheduling of multistate systems mss is developed. In order to find out where companies currently stand regarding predictive maintenance, and where they plan to be in the near future, we surveyed 280 companies in belgium, germany and the netherlands. A read is counted each time someone views a publication summary such as the title, abstract, and list of authors, clicks on a figure, or views or downloads the fulltext.
Jan, 2010 a presentation i gave for people working with predictive maintenance outside the automotive industry based on my experience in the car industry. This second edition of an introduction to predictive maintenance helps plant, process, maintenance and reliability managers and engineers to develop and implement a. In other cases, maintenance alerts will spur a technician into action. Cbm, because it is predictive maintenance, reduces machine life cycle losses and life cycle costs. With predictive maintenance, organizations can identify issues before. The role of vibration monitoring in predictive maintenance. Maintenance planning and parts procurement must be done in real time to make predictive maintenance work, which often exposes a lack of coordination among maintenance, operations, and supply chain teams. A framework to practical predictive maintenance modeling for. With predictive devices currently available, it is incumbent upon. A presentation i gave for people working with predictive maintenance outside the automotive industry based on my experience in the car industry. Combine sensor data with business information in your erp, customer relationship management crm, enterprise asset management eam, and augmented reality systems using sap predictive maintenance and service, part of the sap intelligent asset management solution portfolio. I noticed that most of the answers actually revolved around listing conditionmonitoring techniques that are used as a part of conditionbased maintenance and, in extension, are an integral part of predictive maintenance.
Optimizing maintenance tasks in this way ultimately maximizes the lifespan of equipment and avoids costly disruptions. This typically requires the use of software, which uses asset. The analytic module processes data from the central database. Identify the problem by focusing on failures of specific automatically detect failure patterns, enabling preemptive. Through the utilization of various nondestructive testing and measuring techniques, predictive maintenance determines equipment status before a breakdown occurs. The predictive maintenance team does not continue its efforts to get the maximum benefits that predictive maintenance can provide. An introduction to predictive maintenance sciencedirect. Conditionbased diagnostic approach for predicting the.
By moving from a reactive state to a proactive state, an enterprise can drive truly differentiated business outcomes through predictive analysis of instrumented systems. A framework to practical predictive maintenance modeling. A shortened way of saying predictive and preventive maintenance is pmpdm. Predictive maintenance pdm definition techniques that help determine the condition of inservice equipment in order to predict when maintenance should be performed primary goal minimize disruption of normal system operations, while allowing for budgeted, scheduled repairs. Using predictive analytics to optimize asset maintenance in. Obtaining tools and maintenance requirements 12% 5% travel to and from job site 15% 10% delays in coordination 8% 3% idle at job site 5% 2% late starts and early quits 5% 1% official. Through the utilization of various nondestructive testing and measuring techniques, predictive maintenance determines. Obtaining tools and maintenance requirements 12% 5% travel to and from job site 15% 10% delays in coordination 8% 3% idle at job site 5% 2% late starts and early quits 5% 1% official breaks 10% 10% excess personal time 5% 1% subtotal 65% 35% direct actual maintenance work done 35% 65% good distribution of maintenance activities maintenance. The maintenance schedules are derived from a systemperspective using the failure times of the overall system as estimated from its performance degradation trends. Introduction to predictive maintenance the introduction to predictive maintenance is a threeday seminar designed to give workers an introduction to the methods, procedures, and. With predictive maintenance, manufacturers can lower costs, drive higher output and efficiency, and enhance product quality.
Preventive maintenance principles mit opencourseware. Data from inservice equipment and the support centers is collected and integrated there. Yet, management in many cases does not have the correct information required to make longterm cost effective decisions with regards to the maintenance of the facilities, buildings, infrastructure, utilities, and assets that make parts that make up the final. Oct 24, 2002 this second edition of an introduction to predictive maintenance helps plant, process, maintenance and reliability managers and engineers to develop and implement a comprehensive maintenance management program, providing proven strategies for regularly monitoring critical process equipment and systems, predicting machine failures, and scheduling maintenance accordingly.
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