Road to riches

A survey on predictive maintenance (PdM) discussed in the Plant Engineer's Handbook (2001, Butterworth-Heinemann, Woburn, MA. ISBN 0 7506 7328 1) makes PdM sound like a pot of gold. The survey included 500 plants in a wide variety of industries. Here are some of the benefits reported: "In all surveyed cases," the book reports, "the benefits derived from using condition-based management [PdM]...

06/15/2002


A survey on predictive maintenance (PdM) discussed in the Plant Engineer's Handbook (2001, Butterworth-Heinemann, Woburn, MA. ISBN 0 7506 7328 1) makes PdM sound like a pot of gold. The survey included 500 plants in a wide variety of industries.

Here are some of the benefits reported:

  • Reduction by an average of 55% in the number of catastrophic machine failures

  • Average reduction of 60% in mean time to repair (MTTR)

  • More than 30% reduction in spare parts inventories

  • Average increase of 30% in the useful operating life of plant equipment

  • Availability of process systems increased by 30%

  • Consistent reductions in mean time between failure (MTBF)

  • Reduced potential for destructive failure with a commensurate reduction in potential for injury or death

  • Verification of new equipment condition and installed condition at acceptance

  • Verification of rebuilds and repairs

  • Improved planning and scheduling

  • Elimination of unnecessary repairs.

    • "In all surveyed cases," the book reports, "the benefits derived from using condition-based management [PdM] have offset the capital equipment cost required to implement the program within the first three months."

      That's a pretty impressive list of benefits.

      So, why isn't PdM an active program in every plant? There are many reasons, of course. But chief among them has to be that many plants are not yet up to speed in preventive maintenance (PM), the system that provides the foundation for any PdM program.

      Predictive maintenance is not a hit-or-miss proposition. The monitoring at the heart of the program is time based. That means it requires rigorous scheduling and schedule compliance. And that means PM must be in place first.

      A frequent roadblock to good PM programs is the lack of priority given them by operations and production managers who just aren't all that convinced that PM schedule compliance is important. If you're having that kind of problem, you might want to dangle the PdM carrot in front of them.

      The road to PdM and its potential pot of gold at the end runs through PM.





No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
IIoT grows up; Six ways to lower IIoT costs; Six mobile safety strategies; 2017 Salary Survey
2016 Top Plant; 2016 Best Practices on manufacturing progress, efficiency, safety
2016 Product of the Year; Diagnose bearing failures; Asset performance management; Testing dust collector performance measures
Future of oil and gas projects; Reservoir models; The importance of SCADA to oil and gas
Big Data and bigger solutions; Tablet technologies; SCADA developments
SCADA at the junction, Managing risk through maintenance, Moving at the speed of data
What controller fits your application; Permanent magnet motors; Chemical manufacturer tames alarm management; Taking steps in a new direction
Tying a microgrid to the smart grid; Paralleling generator systems; Previewing NEC 2017 changes
Package boilers; Natural gas infrared heating; Thermal treasure; Standby generation; Natural gas supports green efforts

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
Motion control advances and solutions can help with machine control, automated control on assembly lines, integration of robotics and automation, and machine safety.
This article collection contains several articles on the vital role of plant safety and offers advice on best practices.
This article collection contains several articles on preventing compressed air leaks and centrifugal air compressor basics and best practices for the "fifth utility" in manufacturing plants.
Maintenance Manager; California Oils Corp.
Associate, Electrical Engineering; Wood Harbinger
Control Systems Engineer; Robert Bosch Corp.
click me