How to Do Predictive Maintenance?
How to Do Predictive Maintenance?
How to Do Predictive Maintenance?
How Does Predictive Maintenance Work?
Predictive maintenance uses data collected from the data collection terminal and sensors to evaluate equipment performance in real time. With the help of Internet of Things (IoT) technology, it provides the right tools to collect and analyze equipment data. These data, obtained through predictive maintenance, allow areas to be identified that require attention.
Data Acquisition Terminal and Sensors
Within the scope of predictive maintenance; Data-collecting equipment is deployed to enable evaluation of equipment efficiency and to monitor problems with equipment parts in real time.
Real-time monitoring of equipment is important because in traditional methods this process was carried out manually by maintenance personnel. However, the manual control had a rather big shortcoming. Since the problems that occurred were generally observed in machine parts, detailed investigations were required to be solved.
predictive maintenance; It provides an accurate prediction opportunity for what is happening inside the equipment without any interruption through sensors. These devices measure the value of many parameters, depending on the type of machine.
They are mostly used to measure vibration, noise, temperature, pressure and oil levels, but go beyond that to measure parameters such as electrical current and corrosion.
Internet of Things (IoT)
Collecting data is an important step, but being able to analyze and use data is much more important.
predictive maintenance; It can collect and share data through IoT powered sensors and hardware. It relies heavily on these hardware to connect it to a central system that stores data from the equipment.
Central Hubs collecting data; It can have WLAN and LAN-based connectivity or work using cloud technology. Here, equipment can communicate, collaborate, analyze data, suggest corrective action, or take direct action depending on how the system is set up.
This information exchange is at the center of predictive maintenance. It allows maintenance technicians to understand what is going on with the machines and identify equipment that may need maintenance.
How Do I Apply Predictive Maintenance in My Business?
Preparing a solid ground for predictive maintenance is very important for the sustainability of applications for years. It's a good idea to start with simple transformations and scale up as your business adapts to new technologies.
Here are the general steps your business should take when implementing predictive maintenance:
1- Identify Critical Equipment
Start by identifying critical equipment and systems to be included in the program. Equipment that is production critical and has high repair-replacement costs are often the best candidates for a predictive maintenance program.
2- Create a Database
Another factor to consider for predictive maintenance to be successful is generating actionable insights into machine behavior.
3- Analyze Failures and Develop Models
At this point, it is necessary to analyze the critical equipment that can be applied to the predefined and predictive maintenance method in order to create the failure models of the organization.
4- Make Error Estimates
When identifying the most critical machines and failure models, the next step is to design the correct modeling approach that will form the basis for predictive maintenance failure predictions.
Proper progress of this phase will yield the following outputs:
Monitoring of working conditions through sensors and equipment,
Making sense of and predicting patterns created by data anomalies,
Generating alerts when there are deviations from the specified values.
5- Try it on Pilot Equipment
This is the stage where predictive maintenance is put to the test and validated by applying it to a selected set of pilot equipment.
If the process is carried out correctly, depending on the size and complexity of your business, it may take several months for visible effects to begin, but predictive maintenance will result in significant improvements in your business processes.
Predictive Maintenance Practices in Different Industries
Predictive maintenance is changing the old way of doing things. The principle of "fix before it fails" is adopted, rather than "don't touch it if it's not broken".
Industries and areas of use where predictive maintenance is common:
Predictive Maintenance Study in Production
The increased confidence and sustainability offered by predictive maintenance presents very attractive opportunities for the manufacturing industry. Research predicts that savings from predictive maintenance in the manufacturing industry worldwide could reach $240 - $630 billion by 2025.
The applications of predictive maintenance in production are quite diverse. From managing equipment on the production line to improving worker safety. Especially thanks to the transition from wire-based sensors to wireless sensors; As the cost of sensing technology continues to decline, this trend is very likely to continue.
Automotive Predictive Maintenance Study
Thanks to sensors that collect data and transmit information about the performance of the machines; they started to produce high-tech and smart vehicles. Fleet managers get help from predictive maintenance to proactively plan vehicle maintenance. Drivers, on the other hand, can see warnings based on performance data.
Predictive Maintenance Study in Aviation Sector
Companies serving in the aviation industry use predictive maintenance practices to reduce the costly effects of flight delays and cancellations.
Industry also uses predictive maintenance to help airlines improve aircraft health and prevent catastrophic accidents.
In the next few years, the use of predictive maintenance technologies is expected to increase, as there will be almost no sectors that cannot benefit.