What are the most effective ways to inspect equipment during maintenance?

1 Visual inspection

Visual inspection is the simplest and most common way to inspect equipment during maintenance. It involves looking for signs of wear, damage, corrosion, leakage, or misalignment that could affect the performance or safety of the equipment. Visual inspection can be done by using tools such as flashlights, mirrors, magnifiers, or cameras to enhance the visibility of the equipment parts. Visual inspection can also be aided by using labels, indicators, or color codes to mark the equipment status or condition.

2 Functional inspection

Functional inspection is the next level of inspection, where you test the equipment for its functionality, performance, or output. This involves measuring parameters such as pressure, temperature, flow, speed, vibration, or noise that indicate the equipment condition or efficiency. Functional inspection can be done by using instruments such as gauges, meters, sensors, or analyzers to collect and record the data. Functional inspection can also be done by comparing the actual results with the expected or standard values, or by using software or algorithms to analyze the data.

3 Non-destructive testing

Non-destructive testing (NDT) is a more advanced and specialized way to inspect equipment during maintenance, where you use techniques that do not damage or alter the equipment in any way. NDT can detect defects or flaws that are not visible or measurable by visual or functional inspection, such as cracks, voids, or inclusions in the material. NDT can be done by using methods such as ultrasonic, radiographic, magnetic, or thermal testing to generate images or signals that reveal the internal structure or condition of the equipment.

4 Destructive testing

Destructive testing (DT) is the most extreme and rare way to inspect equipment during maintenance, where you intentionally damage or destroy the equipment to evaluate its properties or performance. DT can reveal the ultimate strength, durability, or failure mode of the equipment, which can be useful for quality control, research, or design purposes. DT can be done by using methods such as tensile, impact, fatigue, or corrosion testing to apply stress or force to the equipment until it breaks or fails.

5 Preventive maintenance

Preventive maintenance (PM) is a proactive and planned way to inspect equipment during maintenance, where you schedule and perform the inspection tasks before the equipment fails or deteriorates. PM can reduce the risk of breakdowns, accidents, or losses, and extend the equipment life and efficiency. PM can be done by using strategies such as time-based, condition-based, or predictive maintenance to determine when and how to inspect the equipment based on its age, state, or trend.

6 Corrective maintenance

Corrective maintenance (CM) is a reactive and unplanned way to inspect equipment during maintenance, where you respond and perform the inspection tasks after the equipment fails or malfunctions. CM can restore the equipment functionality, performance, or output, and prevent further damage or consequences. CM can be done by using techniques such as troubleshooting, diagnosis, or repair to identify and fix the problem or cause of the equipment failure or malfunction.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?