Why Predictive Maintenance is Not Always the Answer: Debunking the Hype

Introduction

As maintenance management experts, we are always looking for ways to optimize our plant maintenance operations. Predictive maintenance has been touted as a game-changer in the field, promising to reduce downtime, increase equipment lifespan, and cut costs. However, the truth is that predictive maintenance is not always the answer. In this article, we'll debunk the hype around predictive maintenance and explore its limitations.

What is Predictive Maintenance?

Predictive maintenance is a maintenance strategy that uses data and analytics to predict when maintenance should be performed on equipment. This is done by monitoring various parameters of the equipment, such as vibration, temperature, and pressure, and analyzing the data to detect anomalies and patterns that may indicate an impending failure. Predictive maintenance can help maintenance teams identify issues before they become critical, allowing for proactive maintenance instead of reactive maintenance.

Is your Maintenance Organization Ready?

Before implementing predictive maintenance, it's important to ensure that your maintenance organization is ready. Here are some of the factors to consider:

Maintenance Planning

Effective maintenance planning is critical for successful predictive maintenance. Your maintenance organization should have a clear plan for implementing predictive maintenance, including identifying which equipment to monitor, selecting appropriate sensors and software, and developing procedures for analyzing and acting on the data. This planning should be integrated with your overall maintenance strategy and aligned with your business goals.

Processes and Procedures

Your maintenance organization should have well-defined processes and procedures for collecting and analyzing data, making maintenance decisions, and communicating with stakeholders. These processes should be documented and followed consistently to ensure that the data is accurate and the predictions are reliable. Your organization should also have procedures in place for responding to false alarms and unexpected failures.

Systems and Tools

Your maintenance organization should have the necessary systems and tools to support predictive maintenance. This includes sensors for collecting data, software for analyzing the data, and a system for tracking maintenance activities and results. Your organization should also have a plan for maintaining and upgrading these systems and tools as needed.

Maintenance Team Maturity

Your maintenance team should have the necessary skills and experience to implement and maintain predictive maintenance. This includes knowledge of data analysis techniques, familiarity with the equipment being monitored, and the ability to interpret and act on the data. Your organization should also have a plan for training and developing your maintenance team to ensure that they are equipped to use predictive maintenance effectively.

Organization Culture

Predictive maintenance requires a culture of continuous improvement and data-driven decision making. Your maintenance organization should be committed to using data to drive maintenance decisions and be open to new ideas and approaches. This culture should be reinforced through leadership support, clear communication, and a willingness to learn from successes and failures.

The Limitations of Predictive Maintenance

While predictive maintenance can be a useful tool, it has its limitations. Here are some of the reasons why predictive maintenance is not always the answer:

• Cost: Predictive maintenance requires specialized equipment and software, as well as trained personnel to analyze the data. This can be expensive, particularly for smaller companies.
• False Alarms: Predictive maintenance relies on data analysis to detect anomalies and patterns. However, not all anomalies and patterns indicate an impending failure. This can lead to false alarms, which can be time-consuming and costly to investigate.
• Human Error: Predictive maintenance relies on accurate data collection and analysis. If the data is not collected or analyzed correctly, the predictions may be inaccurate, leading to unnecessary maintenance or missed opportunities to perform maintenance.
• Unpredictable Failures: Predictive maintenance is most effective at detecting gradual degradation of equipment. However, some failures can occur suddenly and without warning, making predictive maintenance less effective.

When Predictive Maintenance is the Answer

Despite its limitations, predictive maintenance can be a useful tool in certain situations. Here are some instances where predictive maintenance may be the answer:

1.????High-Cost Equipment:

Predictive maintenance may be cost-effective for high-cost equipment, such as turbines, where downtime can be very expensive.

2.????Complex Equipment:

Predictive maintenance can be useful for complex equipment, where failures can be difficult to diagnose and repair.

3.????Critical Equipment:

Predictive maintenance can be valuable for critical equipment, where failures can have serious safety or environmental consequences.

4.????Large Equipment Inventory:

Predictive maintenance may be helpful for companies with a large inventory of?similar equipment, where manual inspections would be time-consuming and impractical and cross learning and horizontal deployment of best practices has good potential.

5.????Availability of CMMS:

Having a comprehensive CMMS in place can facilitate the implementation of predictive maintenance, as it can help track equipment and maintenance data and generate predictive insights.

6.????Availability of Equipment and Maintenance History:

Predictive maintenance can be particularly effective when an organization has a complete record of equipment and maintenance history, as this can enable the generation of accurate and meaningful predictive insights.

7.????Digitalization of Process Assets:

Predictive maintenance can be particularly effective when an organization has fully digitized its process assets, as this can enable real-time monitoring and analysis of equipment performance.

8.????Investment in OT:

Predictive maintenance relies on operational technology (OT) infrastructure, including sensors, SCADA, MES, DCS and Internet of Things. Organizations that have already made the necessary investment in OT infrastructure may be better positioned to implement predictive maintenance.

9.????Actionizing the PdM Analytics:

Predictive maintenance can be particularly effective when organizations have the ability to act on the data generated by PdM analytics, using it to drive real-time maintenance decisions and optimize maintenance operations.

10.?Budget and RoI:

While the implementation of predictive maintenance can require a significant investment, organizations with a clear understanding of the potential return on investment (RoI) may be more likely to see success in their implementation efforts.

11.?Maintenance Team's Expertise and Readiness:

Organizations with a maintenance team that has expertise in data analytics and equipment monitoring may be better positioned to implement predictive maintenance effectively.

12.?Management Vision to Support Emerging Technologies:

Predictive maintenance relies on emerging technologies such as artificial intelligence (AI) and machine learning (ML), and organizations with a clear vision for supporting the implementation of these technologies may be more likely to see success in their implementation efforts.

Summary

Predictive maintenance is not always the answer. While it can be a valuable tool for certain situations, it has its limitations. Companies should carefully evaluate their maintenance needs and consider a variety of maintenance strategies, including reactive maintenance, preventive maintenance, and condition-based maintenance. By taking a comprehensive approach to maintenance, companies can optimize their maintenance operations and minimize downtime.

Contact us for Next Steps

If you're interested in learning more about how to optimize your maintenance operations and reduce costs, contact us at MaintWiz or write to us today to schedule a consultation and demo.

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