Why Machine Proactive Maintenance is the Key to Improve Equipment Health and Uptime

Anything that maintains a machine on the factory floor functional and working properly can be considered as a machine maintenance. The motive of proactive maintenance is to recognize machine failures as something that can be predicted and eliminated before they grow. Generating a proactive maintenance program assists industries find hidden inefficiencies.

Types of Proactive Maintenance

There are several types of proactive maintenance:

Preventive Maintenance (PM)

Preventive maintenance targets to prevent failures and unplanned downtime. This can be done by regularly performing maintenance work before equipment breaks down. This perspective is used on

1. Asset usage frequency
2. Calendar basis
3. Asset history
4. As per the software basis

In this maintenance, all concerns are recognized and errors are eliminated so that unexpected equipment failure is reduced. It also helps to minimize downtime.

As per the Market Research Future, “The Global Preventive Maintenance (PdM) Market is assumed to expand to reach 23,051.4 million in 2025 during the estimated period.”

Condition-Based Monitor Maintenance 

In condition-based maintenance, performance and condition metrics are analyzed in real-time. This enables maintenance managers to plan maintenance work before an issue occurs. 

Scheduled (Periodic) Maintenance

Scheduled maintenance, also called periodic or time-based maintenance is maintenance in which maintenance work is planned in advance, at set intervals. To follow this, manufacturers’ guidelines, as well as the facility’s historical data, are utilized. 

Many industries utilize an integration of these maintenance strategies for several assets or systems. 

How does it Work?

The adaptation to proactive maintenance can be challenging, with concerns of culture change, budget, deficiency of training resources as well as full-time employees to learn and execute the analysis. There are several ways to assist industries to get started, containing :

• Concentrating on failure modes: Priority of plant systems and failure modes with influence on capability and availability
• Getting buy-in from leadership: The business decision of where to spend maintenance resources as well as technologies
• Technologies selection: Addition of available maintenance technologies with wireless abilities
• Improving employee skillset: Improvement in the core capacity of the maintenance team

Common Causes of Asset Failure &  How to avoid them With Proactive Maintenance

There are several possible causes of equipment failure. An appropriate proactive maintenance program can support you to rectify a cause and find a solution before a breakdown happens . Common causes of asset failure involve: 

1. Maintenance Staff Errors 

Sometimes, the work of several maintenance technicians may vary in terms of quality. Make assure that all standard operating procedures (SOPs) are as specified and up-to-date as possible and the technicians can observe them without errors. Invest in staff training and to train them with advanced techniques if required. 

2. Machine Operator Errors 

Machine operators can make mistakes in the way they utilize equipment, which may leads to its breakdown and failure. Again, having specified SOPs and sufficient training procedures in place will help reduce these errors. 

3. Assets Approach the End-of-Life Cycles 

Assets that are approaching the end of their life cycle may fail and require to be fixed more frequently than usual. Sometimes it needs to replace them before their complete failure than to bear increased maintenance costs or potential losses related with downtime. 

4. Hampered Periodic Maintenance 

If the maintenance team requires to skip periodic maintenance activities to fix few more urgent concerns, this improves the risk of machine failures. Execute a solid periodic maintenance schedule and stick to it. 

5. Significant Increases in Production Output 

During a busy time, equipment is more susceptible to wear and tear. Reduce periodic maintenance intervals or implement a condition-based maintenance program to intercept failure. 

Proactive Service for Improving uptime and remote service

Connected assets deliver unusual amounts of data regarding asset condition and performance. Machine production Monitoring system takes equipment analytics and direction to deliver more uptime while assisting technicians to reduce truck rolls and service equipment remotely.

We delivers IoT Enabled Machine Monitoring service to empower remote diagnostics, effective service and precise failure predictions.

Maintenance departments can enhance equipment reliability, minimize unplanned downtime and maintain costs low by executing proactive maintenance plans that resolve small concerns before they become big ones.