For professionals responsible for maintaining machinery and equipment in good condition, predictive maintenance is an indispensable procedure to avoid headaches. After all, that old maxim of "prevention is better than cure" can make a difference in company operations.
However, it's important to emphasize that, in order to implement this step, certain precautions must be taken during its planning for optimization.
So, if you're looking for time optimization, labor and financial resource management, control of the company's status and activities, this article was made especially for you.
Next, we will explain what it is, its benefits, and tips for implementing predictive maintenance in the context of your business.
Keep reading!
What is predictive maintenance?
In summary, this is a method that encompasses practices aimed at equipment maintenance.
Therefore, the process has a preventive character, aiming to avoid potential problems that may arise in the machinery used for activities. In other words, having predictability of failures is the main focus here.
To carry out this step, sensors are installed in the tools to monitor variables such as:
- Temperature;
- Vibration;
- Pressure;
- Flow;
- Electricity.
They generate real-time data that can be monitored using techniques such as analysis of:
- Trends;
- Vibration;
- Oil;
- Electric current.
Through these investigations, the professional can identify patterns or anomalies that indicate potential bottlenecks. As a result, predictive maintenance can be planned in advance, allowing each operation to be performed at the optimal moment.
What is the importance of predictive maintenance?
Considering the context of the Industry 4.0 era, the presence of this prevention is crucial. After all, the higher the demand for products and services, the more the machinery is utilized. As a consequence, the chances of damages and operational failures increase.
Let's say, for example, that in the middle of a workday, a piece of equipment stops functioning. This bottleneck will lead to activity delays, creating a snowball effect and causing financial losses for the organization.
They say time is money, right? So, imagine having to halt your business's production due to operational failures.
This is why predictive maintenance is so important. Monitoring processes would detect potential failures in advance, and you could send a team to resolve the issue. It's as simple as that.
What are the benefits of predictive maintenance?
But putting it into practical terms, do you know what actual benefits predictive maintenance can bring to your company? Below, we will list some advantages of adopting this tool. Take a look:
Greater equipment availability
To start our list, predictive maintenance facilitates the identification and correction of problems before they become critical failures.
As a result, the need for unplanned shutdowns for repairs is reduced, which increases the availability of equipment for use.
Reduction in maintenance costs
By identifying failures in their early stages, this step can help decrease the costs of repairs and equipment replacement.
The direct result of this factor is a better utilization of the resources invested in your organization.
Increased equipment lifespan
Predictive maintenance allows the identification and correction of wear-related issues before they cause permanent damage to the equipment.
In other words, the process promotes the durability of the tool, extending its lifespan and avoiding premature replacement.
Enhanced safety
This method also ensures that machinery is in good working condition.
Thus, there is a reduction in the risks of accidents and operational failures that could jeopardize worker safety and lead to labor-related processes that tarnish your company's reputation.
Improved operational efficiency
It's logical: the condition of the machine is proportional to the level of efficiency it can offer.
What does this mean? Predictive maintenance optimizes equipment performance, reducing downtime and maximizing its utilization.
Better product quality
Last but not least, well-functioning tools result in a quality end product. Therefore, the manager can observe a decrease in defects and rejections.
And what does this lead to? More satisfied customers and increased word-of-mouth marketing, which can place your products ahead of the competition!
6 Tips for Implementing Predictive Maintenance
Now that we understand the benefits of this procedure, we can delve into how to put the method into practice.
Check out our tips below!
1. Define Clear Objectives
Before you start implementing predictive maintenance, it's important to have clear objectives in mind. Define realistic and specific goals. What do you want to achieve?
Among the most common objectives, we can mention:
- Cost reduction;
- Increased equipment availability;
- Improved product quality.
2. Identify Critical Equipment
The next step is to identify the most critical and strategic machines for your company's production process.
These are the equipment that should receive greater attention regarding their analysis.
3. Invest in Technology
Predictive maintenance requires investments in technology, such as sensors, data analysis software, and diagnostic machinery.
We recommend choosing technologies that are suitable for your business needs and can be easily integrated into your systems.
4. Build a Specialized Team
It's also essential to have a specialized team with knowledge in data analysis, monitoring technologies, and machinery maintenance.
This group should be ready to evaluate data, make informed decisions, and perform repairs on the tools if necessary.
5. Establish a Maintenance Plan
A predictive maintenance plan should be established for each piece of equipment, outlining monitoring, analysis, and maintenance activities.
This plan needs to be regularly updated, including clear instructions for the team responsible for the procedure.
6. Measure and Evaluate Results
In addition to all these tips, predictive maintenance should be regularly monitored and evaluated. This way, you can measure whether the objectives are being successfully achieved.
These metrics can include:
- Measurement of equipment uptime;
- Maintenance costs;
- Failure rate and product quality.
Based on this information, the responsible manager can develop the maintenance plan and optimize the resource strategy.
How Technology Can Assist in Predictive Maintenance?
Throughout the article, we've arrived at the following conclusion: technology, such as IoT, should be your ally in predictive maintenance for your equipment.
In this scenario, Squair emerges as the perfect alternative for you to revolutionize the monitoring and control of your company's consumption.
Our solution offers tools that make the lives of professionals seeking to optimize time, labor, and financial resources easier. All of this is done while valuing operational intelligence and environmental responsibility.
Squair provides services that allow you to:
- Reduce Energy Consumption: Lower your electricity bill expenses by up to 25% by knowing exactly who is consuming more.
- Ensure Thermal Comfort: Monitor real-time room temperatures to provide a comfortable thermal experience for your company's employees.
- Offer Data Center Technical Rooms: Automate your air-conditioning systems, securely control critical environments, and receive alerts in case of any risks.
- Enable HVAC System Monitoring: Integrate all of your company's automation systems to understand operations and find the best path to energy efficiency.
Interested in learning more about Squair and enhancing energy management in your company? Follow this link to access more details about our solutions!