Differences between predictive and traditional maintenance

Differences between predictive and traditional maintenance

Probably one of the oldest tasks associated with industrial processes is the maintenance of the machinery used. It is certainly necessary to invest in resources and mechanisms in order to ensure that industrial assets produce in a continuous and predictable way. This also aims to extend the useful life as much as possible. 

Traditional Corrective Maintenance

Traditionally, the only tool of maintenance has been the reactive response to machinery failures. That is, repairing what breaks down as quickly as possible. A good traditional maintenance plan should include both the identification of critical machine parts and ensuring a stock of spare parts. 

In addition, it is recommended to have specialized personnel to solve faults efficiently. In conclusion, the aim is good planning in order to reduce reaction times

An example would be: an engine suffers an irreparable breakdown. How do you act in front of it? is replaced by a new engine.

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Traditional Preventative Maintenance

Traditional maintenance evolved to become the well-known preventative maintenance.

The knowledge of the machinery over the years and the historical behavior that both companies and manufacturers have been able to document, allow to elaborate estimates of useful life of certain machines.

Thanks to this, it is possible to plan maintenance actions in order to replace parts or mechanisms that, according to the statistic, will fail in the short term. Since the cost of replacing a particular piece tends to be more economical than repairing a complete machine, this maintenance branch is profitable.

Preventive maintenance has a clear challenge, which lies in considering the different variables that influence the wear of a piece or mechanism. And why is it important? Most companies invest in preventative maintenance without really exhausting the entire life of the machinery. Sometimes, because of the peculiarity of their production process or the volume of output. The consequence, of course, is that it is assuming a cost that could sometimes be avoided.

An example on this case could be as follows: Given the load to which it is subjected, its useful life and other factors, it is anticipated that a certain motor will fail at 10 years. Therefore, at age 9 it is replaced. The intention is to avoid a hypothetical future flaw. However, this engine may be able to operate for 12 years, but we will never know.

Predictive Maintenance

The increase in consumption, the optimization strategies of the time to shelf and the emergence of disruptive businesses that increase competition has made companies need to optimize their maintenance strategies.

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Thanks to the impact of Industry 4.0, maintenance has evolved to make way for Predictive Maintenance. It is a modality of industrial maintenance that allows to know the operation of machines and equipment by means of non-destructive measurements in order to advance to possible failures and to optimize its performance

Predictive Maintenance Uses the full potential of new industry technologies 4.0 To provide relevant information about the performance of the machinery. This type of maintenance is highly recommended since it also proposes maintenance actions that guarantee the operation and its useful life. A predictive maintenance system is ultimately intended to prescribe specific maintenance actions.

An example of this case would be that by analyzing the behavior of an engine, an anomaly is detected in a component. This anomaly will cause a real failure in the future. The revision and substitution of that particular component is proceeding.

 

Detection

Being able to detect in advance the deterioration of assets and schedule maintenance intelligently, being carried out at the appropriate time.

Real-time measurement

To know in real time the status in order to differentiate within an installation the assets that suffer greater wear depending on their load, as well as the quality of the voltage they are supplying at their output.

Cost reduction

We reduce maintenance costs by performing operations when necessary and avoid unplanned shutdowns or the destruction of critical assets that are difficult to replace in our plant.

Benefits of predictive maintenance

In conclusion, which is more efficient?

he types of corrective, preventive and predictive maintenance share a similarity: they all ensure the continuity of production. However, there are some differences between traditional and predictive methods.

Corrective Maintenance analyzes the fault and tries to correct it by substituting a piece as fast as possible.

The preventive implements systematic measures to replace parts in order to prevent these breakdowns.

Finally, predictive maintenance analyzes the condition of the machine and its failures to predict the next. This precision and effectiveness allows you to drastically reduce maintenance costs

Therefore, the predictive modality is probably one of the most accurate options in terms of industrial maintenance.

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