What Is Predictive Maintenance and Preventive Maintenance?
Knowledge

What Is Predictive Maintenance and Preventive Maintenance?

What is a predictive maintenance strategy? In short, it uses the algorithm to analyze and detect the mechanical state before the failure, and predict the time when the failure occurs. In addition to this, it is also possible to determine the type of proactive tasks that can prolong the service life of the machine.
Published: Jun 15, 2020
What Is Predictive Maintenance and Preventive Maintenance?

What Is Predictive Maintenance and Preventive Maintenance?

Predictive maintenance as an emerging market, because the maintenance strategy shifts from the so-called after-the-fact control method to solve problems by analyzing and enabling predictive maintenance, undoubtedly shows us a market with potential for development. In this market, IoT platform vendors, low-cost secure cloud storage vendors, and analytics providers that provide dynamic data models play a vital role and play an increasingly important role.

The development of the Internet of Things and advanced analytics has driven the entire market to adopt predictive maintenance strategies, resulting in a 25%-30% increase in inefficiency. The report published by IoT Analytics pointed out that the compound annual growth rate (CAGR) of predictive maintenance during 2016-2022 is 39%; besides, by 2022, the annual technical expenditure will reach 1.096 billion US dollars.

The commonly used application levels of predictive and preventive maintenance include condition monitoring hardware, industrial automation hardware, communication connections, storage and platforms, and data analysis.

  1. Preventive maintenance (PM)
    Periodic activities planned to eliminate equipment failures and unplanned production interruptions (time-based periodic inspection and maintenance), it is output of the manufacturing process design.
  2. Predictive maintenance (PdM)
    A method or set of techniques for evaluating the condition of in-service equipment by periodically or continuously monitoring the condition of the equipment to predict the specific time when maintenance should be performed.

How to understand preventive maintenance?

Preventive maintenance and predictive maintenance are important maintenance measures to be considered when implementing total productive maintenance (TPM). Preventive maintenance is the most common, and predictive maintenance is not suitable for every occasion. IATF16949 Clause 8.5.1.5 Comprehensive Production Maintenance Specific requirements for equipment maintenance objectives are given. Predictive maintenance is no longer mandatory but "if applicable".

To put it simply, preventive maintenance refers to scheduled periodic equipment maintenance and replacement of spare parts, usually including maintenance and maintenance, regular use inspection, regular function test, regular dismantling, regular replacement, and other types; periodic maintenance periodic overhaul should belong to preventive the scope of sexual maintenance.

Examples of preventive maintenance:

  • The first maintenance of the new car after 3000 kilometers (replace the engine oil)
  • Regularly clean the production equipment, replace damaged parts and check whether the machinery maintains normal operation

Predictive maintenance is the collection of data and signals (which can be collected intermittently or continuously) by using various means, analyzing and judging the deterioration trend of the equipment, the fault location, the cause and predicting the development of changes, and proposing preventive measures, Prevent and control possible failures. The nature of predictive maintenance is similar to SPC.

Examples of predictive maintenance:

Use thermal imaging cameras, vibration analyzers, ultrasonic instruments and other testing equipment to determine whether maintenance is necessary by detecting the operating parameters of the equipment such as temperature and vibration, and comparing the measured parameters with the standard operating state parameters of the equipment, and How to arrange maintenance work in a targeted manner.

Advantages of predictive maintenance and future trends

The biggest advantage of applying predictive maintenance is the overall cost reduction. Research conducted by the US Federal Energy Management Program (FEMP) estimates that a normally functioning predictive maintenance program can provide savings of 30% to 40% compared to preventive maintenance. According to relevant statistics, on average, carrying out an industrial predictive maintenance program can bring the following savings:

  • Return on investment: 10 times
  • Reduced maintenance costs: 25% to 30%
  • Fault elimination: 70% to 75%
  • Reduced downtime: 35% to 45%
  • Increased production: 20% to 25%

In the actual production process, the incidence of failures is much more difficult to control than imagined: sudden downtime of production lines, delays in troubleshooting, human error, repeated equipment maintenance leads to the additional cost increase and untimely maintenance of equipment wait. We often accept failures passively and carry out maintenance that "can't accurately calculate whether it is the most reasonable" after the failure occurs.

The factory is not only a collection of equipment but also a "living butler". Through intelligent monitoring for preventive monitoring and maintenance, it can tell you the current operating status of various mechanical components, and he can also use the past operating data and the current accumulate running data for real-time monitoring and analysis, predict possible future conditions, and tell you in advance which equipment needs to be maintained and which equipment needs to be replaced. This decision is based on objective data analysis and judgment, avoiding human empiricism; at the same time, early warning gives you sufficient time to prepare for maintenance in advance, to avoid the high cost of sudden shutdown and maintenance, which improves the factory's manufacturing efficiency.

Furthermore, smart factories based on data are everywhere. There will be real unmanned factories. Robot arms replace labor. The operating data of all equipment in the factory will be displayed in front of the managers. Not only to understand the operation status and predict the future, but also automatically trigger work order assignment and self-maintenance, and even self-summarize and learn in the process of continuous error correction to give more reasonable suggestions and implementation plans.

To adapt to the extremely challenging industrial environment, the fields of system engineering, production IT, and business systems must achieve unprecedented integration to increase production efficiency.

Published by Jun 15, 2020 Source :kknews, Source :ilms

Further reading

You might also be interested in ...

Headline
Knowledge
What are the Classifications of Packaging Equipment?
Packaging involves all walks of life. Manufacturers that produce physical products and need to enter the circulation field all need packaging processes, especially in light industry, and packaging equipment is indispensable. With the development of all walks of life, more and more industries use packaging equipment to reduce the labor intensity of the packaging process, improve product quality, reduce investment costs, and improve the labor environment. In the following, we are going to learn more about the common classifications of packaging equipment.
Headline
Knowledge
What is Paint Treatment Technology?
The baking paint treatment can give metal various colors and different textures. It is painted on the metal surface as a surface treatment, which has both protective and aesthetic functions.
Headline
Knowledge
Safety and Use of Woodworking Machinery
Woodworking machine, as the name suggests, is the mechanical equipment used in wood processing. It is a variety of cutting and processing equipment used in the process of sawing logs and processing them into wood products, and furniture machinery is an important part of woodworking machinery. Woodworking machines are the same as machine tools, and can be divided into milling machines, lathes, planers, drilling, rotary cutting, sanding, etc. according to different processing methods. However, do you understand the safety and use of woodworking machinery? Check out the following.
Headline
Knowledge
What is the Importance of Lithography Technology and Mask Aligner in Chip Manufacturing?
Lithography is the most important processing technology of integrated circuits and the most critical technology for manufacturing chips. In the entire chip manufacturing process, the implementation of almost every process is inseparable from the technology of lithography.
Headline
Knowledge
What is A Switching Power Supply? Through Principal Analysis, Understand the Basics In 3 Minutes!
Many people do not know about switching power supply and have always thought that is similar to a linear power supply. Actually, there is difference. The following will explain the principles of basic regarding switching power supplies. Learn with us now!
Headline
Knowledge
Basics to An Electronic Connector
Electronic connectors are also often referred to as circuit connectors, electrical connectors, and conductor devices that bridge two conductors on a circuit so that current or signals can flow from one conductor to another. An electronic connector is a motor system that can provide a separable interface to connect two secondary electronic systems. Simply put, the components used to complete the electrical connection between circuits or electronic machines are called connector.
Headline
Knowledge
What is A KVM Switch?
KVM switches allow you to control multiple computers from a single keyboard, monitor and mouse, increasing productivity, saving space and money. This exclusive feature also provides IT administrators with multiple computers or servers, centralized real-time updates and maintenance.
Headline
Knowledge
What is the Milling Process?
Milling is a machining method in which a milling cutter is used as a tool to process the surface of an object. Milling is a highly efficient machining method in which a rotating multi-blade tool is used to cut a workpiece.
Headline
Knowledge
What is A Punch? Introduction of Punching Principle, Types and Materials
A punch, also known as a punch press, is a forming process technology. There are many kinds of it. Due to different structural principles, the price and processing effect will change in response, but they all have the same structure. With the rapid development of the stamping industry, competition in all walks of life has increased, and it is applied to various industries, such as aviation, education, auto parts, diving equipment and so on. In order to give you a clearer understanding of this technology, the following will introduce you to the structure, types and materials of the punch.
Headline
Knowledge
Common Hand Tools in Our Daily life
Hand tools can be divided into wrenches, pliers, screwdrivers, etc. according to their uses, which are used to assist the assembly, maintenance, or tightening and loosening needs of machines or objects.
Headline
Knowledge
Traditional Casting Process: Sand Casting Technology
The process of pouring molten metal into a mold cavity in the shape of casting, and taking out the finished product after the metal is cooled, is commonly known as sand casting, also known as sand casting. Each sand mold can only be used once, which belongs to destructive casting. Mainly cast steel, aluminum alloy, and copper.
Headline
Knowledge
What is A Five-Axis Machine Tool?
Five-axis CNC machining means that there are at least five coordinate axes (three linear coordinates and two rotary coordinates) on a machine tool, and can be processed simultaneously with coordinated movements under the control of the computer numerical control system. The axis of the CNC machine tool means the motion axis, which is actually a coordinate axis in space, such as the XY axis of the coordinates. There is no motion axis with an independent controller and motor drive system.
Agree