October 2019

M achine breakdowns are normal occurrences in the manufacturing industry. The repetitive functions of each machine inevitably lead to failures and downtime. The trouble with this, of course, is that manufacturing today requires greater levels of efficiency and quality output. Any equipment failures resulting in unplanned downtime can lead to service delays, disgruntled customers, and possible losses in terms of productivity and income. Predictive maintenance vs. reactive maintenance First off, Martin Thomas, European marketing manager at Radwell International Ltd explains we need to distinguish predictive maintenance from reactive maintenance (which more people are familiar with). The former is a process 28 | Plant & Works Engineering www.pwemag.co.uk October 2019 Smart Maintenance Management Focus Predictive maintenance – impact and value to manufacturing Technological innovation, such as the development of industrial IoT (Internet of Things) has made it possible to use machine data to improve operational performance and process efficiency. The availability of IoT has made it possible to optimise the remote monitoring and maintenance capabilities it offers to minimise the costs and consequences of both planned and unplanned downtime. This is a process commonly referred to as predictive maintenance. But even with these benefits, some manufacturers have yet to adopt it. PWE reports. whereby the maintenance requirements of machinery in a production facility or factory are anticipated. Reactive maintenance, as most of us already know, is when machines are serviced or repaired only when they actually fail or break down. Based on this differentiation, Thomas says it would be easy to understand that reactive maintenance leads to substantial costs in terms of the kind of repair work required or even the possible need for replacement. In some cases, due to one part failing but not being attended to or addressed, other parts get damaged as well when this could have been easily avoided. Moreover, unexpected breakdowns significantly impact production output and quality, and any delays in production negatively affect the bottom line. As opposed to reactive maintenance, predictive maintenance utilises data collected from each machine based on its normal pattern of operation or performance. Any minute changes or inconsistencies with the baseline data detected by sensors will lead to subsequent alerts so that operators can reasonably predict the necessity for maintenance work. This way, any damage or fault remains isolated, so other parts remain unaffected, and total equipment failure is avoided. Benefits of predictive maintenance When it comes to preserving the lifespan of machines, predictive maintenance is the clear winner. Moreover, it offers manufacturing entities the following additional advantages: 1. Reduction of unexpected failures and downtime. Since by its very nature, predictive maintenance is anticipatory, it effectively reduces and may even eliminate the incidence of unexpected equipment failure. This, in turn, can significantly reduce the incidence of downtimes or service interruptions. 2. Reduction of maintenance expenses. Predictive maintenance helps manufacturers avoid costly repairs and or replacement of parts or machines because the fault is detected, isolated, and fixed before severe machine damage occurs. Moreover, since preventive maintenance is intended to preempt significant damage to equipment, there will be no need for extensive repair work as well as emergency servicing. 3. Reduction of repair and overhaul time. Machine faults are diagnosed before they