As technology continues to advance, the maintenance of industrial assets has become an increasingly complex task. The pressure to reduce downtime, improve efficiency, and reduce costs is higher than ever. This pressure is what has led to the development of two types of maintenance methods: Predictive Maintenance (PdM) and Preventive Maintenance (PM). Predictive maintenance technology predicts equipment failures before they occur, while preventive maintenance involves the routine inspection and servicing of equipment before it breaks down. In this blog post, we will compare the benefits of both methods and determine which is more cost and time-efficient.
Predictive Maintenance
Predictive maintenance involves the use of advanced technology such as sensors and data analytics to predict equipment failure before it occurs. With PdM, the data collected from sensors on equipment is analyzed to determine potential issues. This analysis helps maintenance teams to identify the root cause of the problem and make necessary repairs or replacements. Predictive maintenance is considered more efficient than other maintenance methods because:
- It enables maintenance personnel to schedule repairs or replacements during planned downtime and avoid incurring unplanned downtime.
- It eliminates the need for regular inspections since it only requires a diagnosis when a problem occurs.
- It saves time and money in the long run by reducing the cost of replacement parts and labor expenses.
Preventive Maintenance
Preventive maintenance, on the other hand, involves conducting routine inspections and cleaning services. The goal is to prevent equipment failure by identifying potential issues early on and implementing the necessary repairs or replacements. However, preventive maintenance has its shortcomings, including:
- It can be expensive over time as it involves conducting regular inspections and replacements.
- It can cause unnecessary downtime if maintenance personnel replace parts that were not causing issues.
Which is More Time and Cost Efficient?
To determine which method is more time and cost-efficient, we need to look at the numbers. According to a study by Plant Engineering, predictive maintenance can reduce maintenance costs by up to 25% and increase uptime by up to 45%. On the other hand, preventive maintenance can reduce equipment downtime by up to 18% but can be 3-5 times more expensive than predictive maintenance.
While PdM has higher upfront costs, it can save companies money in the long run as they can detect potential issues and schedule maintenance during planned downtime. Preventative maintenance requires regularly scheduled maintenance checks, increasing maintenance costs and downtime.
Conclusion
Overall, predictive maintenance is more cost and time-efficient than preventive maintenance. The technology used in PdM provides maintenance personnel with valuable information to plan and execute repairs and replacements during planned maintenance. In contrast, PM is reactive, requiring frequent inspections to spot potential issues limiting productivity.
In conclusion, both maintenance methods are essential for the maintenance of industrial assets, and the choice of maintenance method depends on the specific industrial asset's needs. However, if cost and time are vital factors, predictive maintenance provides a cost-effective solution.
References
- "Predictive maintenance vs. preventive maintenance: What's the difference?" . IBM Watson IoT Blog
- "Predictive vs preventative maintenance: what's the difference?" Fiix
- "Predictive Maintenance or Preventive Maintenance?" Plant Engineering.