Establishing a Predictive Maintenance Programme

1. Establishing a Predictive Maintenance Programme Adam Adgar School of Computing and Technology

2. Introduction • First steps towards • Tighter control of costs • Improving process efficiency • However in practice many programs are aborted within first few years • Need to be able to • specify goals of programme • quantify benefits achieved • Requires • Initial capital costs • Annual maintenance

3. Goals • Minimise • unscheduled equipment failures • maintenance costs • lost production • Improve • Production efficiency • Product quality • Regular monitoring of parameters defining operating condition of the plant

4. Outline Stages • Obtain management support • Determine existing maintenance costs • Define goals and objectives • Develop requirements of the system • Select a system • System Development

5. Baseline Costs • Staffing • Spare Parts Inventory • Percentage unscheduled to scheduled maintenance repairs • Repair costs on critical plant • Annual plant availability • Incremental costs of production caused by failures

6. Mobley (2002) Example Objectives • Eliminate unnecessary maintenance • Reduced lost production caused by failures • Reduce repair parts inventory • Increase process efficiency • Improve product quality • Extend operating life of plant systems • Increase production capacity • Reduce overall maintenance costs • Increase overall profits

7. Functional Requirements • Management support • Investment in capital expense and labour • Record keeping and information exchange procedures • Dedicated and accountable staff • Full-time team to focus on the task • Accountability through performance measures • Efficient data collection and analysis • Structure monitoring tasks to emphasise goals • Consistent approach to machinery in plant • Take into account criticality issues • Define methods, schedule, analysis and reporting • Viable database • Choice of system • Assistance from consultants

8. Mobley (2002) Justifying PdM Programmes • Formulate a detailed Program Plan • Know your Audience • Create Implementation Plan • Do your homework • Take holistic view • Obtain absolute buy-in

9. Selecting a PdM System • Hardware and software to support the techniques chosen. • System requirements • Automated data acquisition, processing, storage • Flexibility • Reliability • Accuracy • User friendly • Training and Technical support • Cost (Purchase and Operating)

10. System Specifications • Microprocessor • Operator expertise • Accuracy of data • Alarm limits • Data Storage • Data transfer • Host PC • Software • Transducers

11. Database Development • Establishing data acquisition frequency • Set up analysis parameters • Setting boundaries for signature analysis • Defining alarm levels • Selecting transducers

12. Summary • Outlined stages of implementation of predictive maintenance programme. • Importance of goals and objectives. • Discussed typical problems encountered in practice.

13. References • Mobley, K. (2002)An Introduction to Predictive MaintenanceButterworth-Heineman, 2nd Ed