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Save Money, Boost ROI and Enhance OEE with Predictive Maintenance

Posted February 12, 2017 12:01 AM by Designerz

In order to save money you need to spend money – especially when financing predictive and preventative maintenance solutions for high-capital assets. In this case, even a relatively modest spend could potentially offset repair or lost-production costs that run into millions.

However, maintenance spend is, understandably, very hard to quantify in terms of its benefits, especially if nothing actually goes wrong; even more so when you couple it to budget competition from other disciplines.

In many instances computerised maintenance management system (CMMS) can help define a strategy and timetable and remove much of the guesswork and workload by determining the actual work to be undertaken on individual machines and assets.

This proactive approach is often supported by specialist products that offer a real-time snapshot of machine health. Such solutions range from simple temperature sensors and vibration probes all the way up to bespoke, fully featured condition monitoring (CMS) software and Artificial Intelligence (AI) solutions.

Wear is often the primary issue in mechanical systems and can result in reduced tolerances, elevated heat levels, less than smooth movement and the loud squeals and grinding noises that foreshadow something going seriously wrong. The good news is, with proper servicing and regular observation, mechanical systems can easily match and even exceed the predicted overall life of the machine.

Heat generation can actually be used to your advantage thanks to the ability to measure it using simple, inexpensive temperature sensors. One example would be the PN151 NFC Infrared Temperature Sensor from Calex. By mounting a sensor like this near potential wear points, operators can be quickly made aware of any issues. Another approach would be to use thermal-visualisation solutions, such as those offered by FLIR, which are designed to highlight hotspots.

In rotating equipment, wear can also be accompanied by vibration. In this case, specialist vibration sensors, such as those from SKF, can measure multiple vibration patterns and then differentiate between normal and abnormal signals. They can even highlight specific failure modes through advanced frequency analysis. These predictive maintenance products form an integral part of the range of RS solutions for customers looking to establish an effective plant maintenance programme.

Looking higher up the technological scale, we are also seeing a new advent of software-based approaches, with some companies providing AI-based analytical solutions for maintenance operations – providing even more depth and real-time problem-solving capabilities to what is a vital function.

Maintenance expenditure should always be seen as something that can increase overall equipment effectiveness (OEE), enhance return on investment (ROI), lower repair costs, reduce damage and contribute to increased or maintainable product quality. And these are the tangible benefits that have to be at the forefront of any expense justification.


Editor's note: This is a sponsored blog post by RS Components.

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Join Date: Feb 2013
Posts: 1299
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#1

Re: Save Money, Boost ROI and Enhance OEE with Predictive Maintenance

02/14/2017 4:58 AM

The world is run by bean counters who only have one aim, bottom line profits. Commonly termed as, 'What is in it for Me?"

Most companies see preventative maintenance as a cost they can save, but never see the bigger picture of doing maintenance, can reduce down times and maintain productivity.

Sadly, profits & loss and numbers is objective No1 these days.

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Guru

Join Date: Jul 2012
Location: Madison, WI.
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#2

Re: Save Money, Boost ROI and Enhance OEE with Predictive Maintenance

02/14/2017 10:30 AM

When the world miraculously ends every month and then miraculously starts up again right where it left off, there is no need for predictive maintenance because it's on somebody else's quarterly.

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Join Date: Aug 2007
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#3

Re: Save Money, Boost ROI and Enhance OEE with Predictive Maintenance

02/14/2017 4:11 PM

Unfortunately, you are "singing to the choir" when you should be talking to the managers.

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