Are you taking the Preventive or the Reactive path?
Or are you even Predicting your maintenance?
Most of us are happy that airlines do not assess the maintenance as a reactive action.
We all have hopes that failures are eliminated by a maintenance schemes and that the airlines are always may eliminate failures but prediction and preventive methods.
In general, maintenance falls into two categories: proactive or reactive.
Proactive, or preventative maintenance, however, focuses on avoiding repairs and asset failure through preventive and predictive methods.
Reactive maintenance focuses on repairing an asset once failure occurs.
But what exactly are preventive and predictive maintenance?
And what’s the difference between them?
The Different Approaches
To give a full view of the benefits associated with proactive approaches to maintenance, I’ll compare preventive and predictive methods with the run-to-failure approach:
Although industries like food, fuel and manufacturing have invested in proactive maintenance, some are still stuck in a reactive mindset.
And most RMC plants are definitely taking the track of run-to-failure.
Actually just over half of U.S. companies (55%) have a run to failure approach to maintenance.
Suggested by the name, the intention of a run to failure method is to operate an asset until it breaks. Repairs are then made, bringing the asset back to operational condition.
There is typically no maintenance conducted between failures unless a technician or maintenance manager happens to notice a need for it.
This approach initially seems like a cost-effective strategy. However, the inconsistent nature of breakdowns makes it hard to prepare labor and parts for repairs, resulting in unplanned expenses associated with lost productivity, overtime labor and spare part storage/purchasing.
Preventive maintenance involves regularly performed, planned tasks that are scheduled based on either time passed or meter triggers. This is done to reduce the possibility of asset failure.
Periodically checking, cleaning and maintaining equipment increases an asset’s life span, making it more reliable. These scheduled tasks also reduce downtime, directly impacting overall productivity and company profitability.
Ideally, this method has an 80/20 planned maintenance ratio – meaning 80% of maintenance initiatives should be planned while the remaining 20% can be unexpected repairs.
Although a preventive maintenance strategy requires a significant time investment to schedule, prepare and delegate tasks, the efforts are more cost-effective than a run to failure strategy. And facts are that “a company can save between 12% and 18% using preventive maintenance versus reactive maintenance.”
12-18% on just the maintenance, then add additional uptime and utilization benefits.
Not only are you in control of your production, but also related costs.
But what is Predictive maintenance?
Predictive maintenance (PdM) is maintenance that monitors the performance and condition of equipment during normal operation to reduce the likelihood of failures. Also known as condition-based maintenance, predictive maintenance has been utilized in the industrial world since the 1990s.
The goal of predictive maintenance is the ability to first predict when equipment failure could occur (based on certain factors), followed by preventing the failure through regularly scheduled and corrective maintenance.
Predictive maintenance cannot exist without condition monitoring, which is defined as the continuous monitoring of machines during process conditions to ensure the optimal use of machines.
So, find those critical parts of your RMC. Start monitoring them. Gather data and analyze.
Might sound like a big step? But remember, its a step towards higher utilization and cost reduction.