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.



Top Plant
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Product of the Year
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System Integrator of the Year
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
May 2018
Electrical standards, robots and Lean manufacturing, and how an aluminum packaging plant is helping community growth.
April 2018
2017 Product of the Year winners, retrofitting a press, IMTS and Hannover Messe preview, natural refrigerants, testing steam traps
March 2018
SCCR, 2018 Maintenance study, and VFDs in a washdown environment.
April 2018
ROVs, rigs, and the real time; wellsite valve manifolds; AI on a chip; analytics use for pipelines
February 2018
Focus on power systems, process safety, electrical and power systems, edge computing in the oil & gas industry
December 2017
Product of the Year winners, Pattern recognition, Engineering analytics, Revitalize older pump installations
Spring 2018
Burners for heat-treating furnaces, CHP, dryers, gas humidification, and more
April 2018
Implementing a DCS, stepper motors, intelligent motion control, remote monitoring of irrigation systems
February 2018
Setting internal automation standards

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

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