The global market for Predictive
Maintenance is projected to reach US$10 billion by 2025, driven by the growing
value of predictive intelligence in asset management. Given that effective plant
asset management and maintenance is the cornerstone for achieving excellence in
manufacturing productivity, there is significant focus shed on technologies that
help in more smart and efficient asset monitoring and maintenance. Legacy
maintenance programs which are primarily static in nature and characterized by
time-based manual inspection are growing out of favor and are being replaced by
newer concepts such as predictive maintenance (PdM).
Defined as a strategy where maintenance
is scheduled at a future date based on analysis of sensor data measurements,
PdM is proactive and is designed to increase reliability of machine and
decrease their downtime. PdM is an
advanced form of maintenance that offers benefits over and above
condition-based maintenance (CbM) which utilizes real-time sensor measurements
to identify if a machine or its components have reached a point of failure and
then schedule maintenance. Benefits of PdM include advanced prediction of
maintenance need; reduces unexpected downtime by over 50%; enables automation
of maintenance tasks and reduces repair and overhaul time by 60%; helps in cost
savings to the tune of 30% to 40%; timely verification/inspection of equipment;
reduction in machine failures; reduction in maintenance costs; over 30% reduced
need to maintain inventory of spare parts; extended service life of machines
and components and higher equipment ROI; increase in production productivity by
over 25% and uptime by 30%; improved operator safety; and over 50% increase in
revenues achieved via faster time-to-market. Higher revenues and profits are
also associated with improved product quality and reduced risk of manufacturing
faults which pushes up the cost of reprocessing. Read More…
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