The cost value of predictive and preventative maintenance

Predictive and preventative maintenance are two sides of the same coin. Both strategies work to keep equipment functioning properly and reduce downtime. Predictive maintenance aims to ‘predict’ when maintenance is going to be needed based on tendencies, whereas preventative maintenance offers routine servicing to ‘prevent’ failure. Applying these techniques to a plant full of diverse, interconnected equipment can result in significant time and money saved. 

One important component needed to execute these strategies effectively is better information. This includes an uninterrupted and complete dataset which is achievable using energy harvesting sensors. As opposed to battery or plug-in sensors, energy harvesting sensors are self-powering, maintenance-free, unsusceptible to battery failure and allow for more frequent data reporting with an always-on connection of equipment and assets.

Once sensors begin monitoring equipment and machines, data is sent to a cloud-based dashboard that understands and interprets the information into a rich and robust dataset. By seeing this information in real time, engineers can see how machines are functioning at all times without physically being on-site. Furthermore, alerts are automatically generated through the dashboard when system inconsistencies occur or as a reminder for maintenance servicing. Additionally, historical record keeping capabilities allow engineers to view and compare an equipment’s performance over time. As a result, they can easily identify anomalies and patterns that can lead to malfunctions. By seeing these ‘first steps’ to failure, engineers can perform the ‘predictive’ maintenance required proactively and prevent costly breakdowns before they occur. 

Without predictive and preventative maintenance, costs can easily add up to include the breakdown of equipment, maintenance materials, overtime hours or subcontractors and unplanned downtime. As a solution, DCO Systems offer energy harvesting sensors and software that provide better information and give engineers the advantage of viewing equipment as needing predictive and/or preventative maintenance. It’s not a coin toss on one or the other, the cost value of predictive and preventative maintenance is greatest when executed together. To find out more go to dcosystems.co.uk email: info@dcosystems.co.uk or call: 01285 359059.