Predictive maintenance is the most advanced form of maintenance. This is the third and most complicated kind of support. There are three different types of maintenance; corrective, preventive and predictive. All of this is very different, but if you can do predictive maintenance correctly, there will be advanced lines for any competition. Predictive maintenance includes monitoring the real-time condition of equipment and components and then predicting their remaining lives. To explain it thoroughly, I must give a brief overview of corrective and preventive maintenance as well.
Corrective maintenance involves repairing a problem when equipment or components fail. The simplest examples are a car. If you buy it new and drive around it without any support, the engine, steering line or anything else will fail. Corrective maintenance will determine what breaks (when they occur) and then continue pushing them until something else breaks.
Preventive maintenance, on the other hand, involves the use of predefined tables. These tables are often simply searches or can be set to work for changing components. The idea is simple to correct problems before they become a problem. Preventive maintenance is applied to all cars. You can change oil and coolant, as well as other components before they cause a problem.
Corrective maintenance is the worst regarding costs because it revolves around high downtime and poorly planned planning. Preventive maintenance is a step up, but it also has problems. A lot of equipment will have a proposed change of parts in a given period. The elements that are changed are rarely fully functional. What this means is that you can still change half the remaining portion of life and you will not know it. Like wisdom, what is the purpose of stripping a piece of equipment down if it is in an authentic state?
Would not it be great if you could only determine the state of the stomach (and what it wore and how much life it had)? Predictive maintenance uses some tools ranging from oil analysis to thermal imaging and vibration analysis. By using these tools, you can determine the state of the equipment and then predict how long it will take (also very accurately). This way, you will get the most out of gear and parts while eliminating the risk of unplanned downtime. If you can predict that material will fail within 500 hours (based on vibration analysis or other predictive maintenance), you can schedule a 450-hour reconstruction.
Predictive maintenance is also used to reduce damage to machinery. Some vibration analysis units are put in place to turn off a piece of equipment if they degrade rapidly. Take the turbine for example. If vibrations occur and are not quickly stopped, instead of replacing some cheap parts, you can reach an entirely new turbine (as it is self-destructive). I highly recommend predictive maintenance, as it is by far the most advanced in any industrial application. Andromeda is an enterprise asset management company that does predictive maintenance for various companies.
Principles of Maintenance Scheduling.
The maintenance schedule is a compressive or detained list of all maintenance action and their methods and time of their execution. In other words, it may be defined as a document or a detailed report. A scheduled program thus prepared should be followed strictly. The schedule should be in detail specifying the points requiring daily, weekly, monthly and yearly attention.
The following principle can develop an active maintenance schedule.
The schedule must be done in two ways
Long term schedule two or three weeks in advance
Short term schedule just a week or two in advances.
A long term schedule will help in preparing and planning for material, spares, tools, and test equipment; it will also assist in obtaining consent for maintenance. The short term schedule will be finally broken up into daily maintenance schedules for day to day implementation and for assuring that close control would be exercised.
The maintenance schedule should be based on preplanned methods, activities.
The total systems ought to be clear and understandable and at the same time simple to operate and to implement.
The schedule should be revised periodically. This can be achieved by keeping aside approximately 20% of the capacity for nonpriority tasks. Such cushioning can take care of the emergency or priority jobs that would be available e during this period. These can be accommodated without causing any significant work disruptions by switching over this capacity towards more critical needs.
The maintenance requirements have to be carefully balanced against the available capacity to accomplish the tasks.
Relevant information like backlog report, workforce availability report and mate4rials and spares availability report are critical. Backlog report is a list of unattended, or if attended, then incomplete jobs, with an indication of estimated person-hours required for each. This is used for feeding on to the schedule of newly indented items so that pending tasks can be scheduled and attended to.
The production plan is issued by the operations department and includes machine loading and utilization plans. It helps maintenance staff to schedule machine repairs to a convenient time and opportune moment.
Any visual aids like wall charts or scheduling boards should be made use of, which show jobs status, the date of issue of work orders, the work progress, long pending jobs, etc. this makes it easy for all concerned to obtain the latest information or status of work.