Predictive maintenance involves utilizing data from instrumented machinery to determine when servicing or overhaul is necessary. By doing so, maintenance efforts and expenses can be reduced while improving the availability of equipment.
However, the practical implementation of predictive maintenance often encounters resistance. Running a predictive maintenance pilot program serves as a means to gather data that can persuade skeptics and showcase a return on investment. It also aids in refining the rollout process for larger implementations.
This article delves into the process of implementing predictive maintenance, beginning with a small-scale demonstration. By detailing the steps involved and discussing the expected benefits, it provides a roadmap for developing a predictive maintenance strategy.
Steps to Implement a Predictive Maintenance Pilot
A predictive maintenance pilot program serves two main objectives: to gather the necessary data to justify broader implementation and to identify when adjustments in approach are required to maximize benefits. Additionally, it helps in winning over detractors who may have reservations about predictive maintenance.
The following 10 steps outline the essential components of a predictive maintenance pilot plan.
#1: Define Objectives and Criteria
Establish objectives and criteria for measuring progress. It is crucial to set a budget as part of defining objectives, as this will determine the types and quantities of sensors to be deployed.
Common objectives include:
- Reduce downtime or increase availability
- Extend equipment life
- Reduce maintenance expenses
Measurement can be done through mean time before failure (MTBF), availability, or financial metrics, among others.
Benefits of Predictive Maintenance Programs
Industrial maintenance is primarily focused on ensuring machinery is operational when needed, at the required level of performance and quality. While many plants rely on planned maintenance strategies, predictive maintenance offers several advantages:
- Eliminates unnecessary maintenance work
- Better maintenance scheduling
- Reduced spare parts inventory
- Higher machine availability
- Increased maintenance technician engagement
Get Support Deploying Predictive Maintenance
While predictive maintenance offers compelling benefits, its adoption can be met with resistance due to implementation costs and perceived benefits. Implementing a pilot program can address these concerns, allowing stakeholders to gather data, iterate on their approach, and align on objectives.
This blog provides a detailed outline of ten steps for creating and executing a predictive maintenance pilot. While this serves as a foundational guide for those embarking on this path independently, partnering with experienced predictive maintenance services providers can offer valuable insights and strategies for a successful implementation.