Breadcrumbs
Unexpected Equipment Failures
Continuous machine operation is paramount for many industries.
Introduction
Unpredicted machinery downtimes in industries result in production halts, financial losses, and operational inefficiencies.
Core Problem
Traditional maintenance schedules are calendar-based, ignoring the actual health and performance of the equipment.
In many industries, the smooth operation of machinery and equipment is paramount. Unexpected breakdowns not only disrupt the workflow but can also incur high costs, both in repairs and lost productivity. The traditional approach to maintenance, however, is fraught with inefficiencies:
Reactive Maintenance Pitfalls
Many businesses follow a reactive maintenance strategy, addressing equipment issues only after they arise. While this might seem cost-effective initially, the unforeseen breakdowns can result in prolonged downtimes, expensive urgent repairs, and even potential collateral damage to other parts of the system.
Calendar-Based Limitations
Scheduled or calendar-based maintenance, where machinery undergoes routine checks irrespective of its condition, is another common strategy. This method, while better than a purely reactive approach, can lead to over-maintenance of some equipment and under-maintenance of others. It doesn't consider the actual wear and tear machinery undergoes.
Wasted Resources
Over-maintenance results in wasted man-hours and replacement parts. Equipment might be taken offline for checks even if it's in perfect working condition, leading to unnecessary production halts.
Inefficient Use of IoT Data
Many modern machines are equipped with sensors that collect vast amounts of operational data. Traditional maintenance methods often underutilize this goldmine of information, relying instead on generic schedules or visible signs of wear.
Safety Concerns
Unexpected equipment failures aren't just a productivity concern; they can also pose safety risks. Machinery that breaks down during operation might endanger workers, especially in industries like manufacturing or energy.
Lack of Predictability
Without a predictive approach, businesses find it hard to plan around maintenance. This lack of predictability can disrupt supply chains, lead to missed delivery deadlines, or cause inventory pile-ups.
Resolution
The Predictive Maintenance platform anticipates equipment failures before they happen, enabling businesses to perform maintenance based on actual equipment health rather than arbitrary schedules.