From Selecting the Right Manufacturing Improvement Tools: What Tool? When?

You can't predict anything with predictive maintenance.
Ron Moore


Let's begin this chapter with the above admonition: you can't predict anything with predictive maintenance, or PdM as it is often called. Why then is it called predictive maintenance? The source of the name is likely lost in the fog of history, and the name is at least 20 years old. What you can do with PdM is understand the condition of your equipment, and based on certain standards or measures, you can detect an anomaly or the onset of failure, and anticipate that the equipment will eventually fail. Based on the severity of the condition and the consequence of failure, you can determine an appropriate priority and course of action to minimize the risk and consequence of the pending failure. You cannot predict when a machine will fail with any particular accuracy, but you can identify when the probability of failure has increased. A much better phrase for PdM is Condition Monitoring (CM), a phrase that will be substituted as appropriate in this chapter.

Cost Reduction Benefit of CM

The most common form of industrial CM, vibration analysis, has existed since the early 1970s, and there have been any number of studies that have provided compelling evidence of its business benefit. One of the more recent sets of data available that provides a compelling case for the use of CM technologies is provided below in Figures 13-1 and 13-2, which shows correlation coefficients of maintenance costs and two...

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Products & Services
Predictive Maintenance and Condition Monitoring Systems
Predictive maintenance (PdM) systems and condition monitoring systems are used to predict equipment maintenance, and to monitor corrosion, oil condition, bearing wear, overheating and other parameters than can lead to the breakdown of capital equipment.
Condition Monitoring and Machine Maintenance Services
Condition monitoring and machine maintenance services monitor the condition of critical machines, battery banks, power supplies, processes and rotary equipment. They also perform predictive maintenance (PdM) and/or preventive maintenance.
Vibration Transmitters
Vibration transmitters provide electrical outputs that are proportional to vibration inputs. They are used during predictive maintenance in order to reduce unexpected machine failure.
Tool Monitors
Tool monitors optimize machine tool operating conditions based on feedback from a sensor or probe.
Electrical Maintenance Services
Electrical maintenance services perform electrical system testing, efficiency analysis, reliability determination, safety checks, and scheduled shutdowns of electrical assets such as motors, transformers, power supplies, and co-generation systems. The upgrades and repairs that they perform help to prevent costly downtime.

Topics of Interest

A pessimist sees the difficulty in every opportunity; an optimist sees the opportunity in every difficulty. Winston Churchill Introduction Robert Nelms' has said that Root Cause Analysis (RCA)...

1 Predictive Maintenance Basics 1. 1.1 The maintenance philosophy of operating the machine until it fails is called: Breakdown maintenance Proactive maintenance Predictive maintenance Preventive...

Overview This chapter discusses the techniques that are most commonly used by maintenance departments to ensure equipment reliability: preventive (PM) and predictive (PDM) maintenance programs. The...

Jo lle Courrech, Ronald L. Eshleman INTRODUCTION Condition monitoring of machinery is the measurement of various parameters related to the mechanical condition of the machinery (such as vibration,...

Overview Predictive maintenance is the monitoring of equipment operating conditions to detect any signs of wear that is leading to a failure of a component. The goal of the predictive maintenance...