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]...
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.
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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