Basic Care #1 covered keeping your machinery components tightened, clean, and lubricated on a regular basis. Done properly, your breakdowns should be greatly reduced (results of up to 80% have been achieved). The next step in further reducing breakdowns and increasing plant capacity involves using Predictive Maintenance (PdM), technology that detects when machinery is beginning or about to fail (potential failure).

  With PdM you are able to plan and repair machinery before it actually fails, usually at a much cheaper cost and at a more convenient time than if the machinery actually fails. The three most commonly used technologies are Vibration Analysis (rotating equipment), Oil Analysis (most wetted systems), and Infrared Thermography (any object where temperature variations are a sign of failure). There are many other forms of PdM, and most technologies are non intrusive as they are performed with the machinery operating.

  To keep costs under control apply PdM only where needed, on your most critical equipment. Criticality of your equipment should be determined on a plant wide priority basis and of course varies from plant to plant and industry to industry. Use risk assessments, consequences of failures (process stoppage, environmental damage, financial losses etc), the possibility of secondary damage, availability/ price of parts, and other criticality rating systems that are specific to your organization to determine where to economically apply PdM in your facility.

  Some benefits to implementing a PdM program include increased capacity (uptime), increased quality, increased safety, increased lifespan of equipment, lower overall maintenance costs, as well as other safety, environmental and financial benefits.

  Other items to consider when implementing a PdM program include hiring contract services or using in house monitoring, proper frequencies for sampling, proper tactics for acting on recommendations or reports, and accurate record keeping to compare reports and create trends. If you have any questions or thoughts about Predictive Maintenance (PdM) Technology or on how to implement this tactic into your facility please contact me through my profile, I will be more than happy to answer any questions.