How do I select assets for predictive maintenance?
Answered May 01 2019
Choosing assets for predictive maintenance is a matter of priority, especially starting out. A few of the factors you’ll want to look at include:
- Criticality – The more essential an asset is to your process, the more you’ll want to keep it from failing.
- Cost to replace – Often, companies will use PdM on expensive assets since they cost more to replace.
- Failure history – An asset with a history of failures is a likely candidate. About 80% of mechanical assets have no major faults, so this narrows things down quite a bit.
- Ease of access – The harder an asset is to reach, the more it tends to be overlooked or ignored during regular maintenance checks. As such, you might want to monitor it remotely.
- Current maintenance costs – If you’re already doing regular preventive maintenance checks on an asset, shifting over to PdM could cut down on those costs. The switch will also be a bit easier if you’re already performing PM.
Basically, this boils down to evaluating the overall cost savings of implementing PdM on the asset. Some are more worth protecting than others, and looking at these factors will help you assess that.
If you’re just starting a PdM program, I’d recommend choosing one asset based on the above criteria. A critical asset with a failure history would probably be a good candidate. As you install the needed equipment and incorporate that into your CMMS, you’ll be able to gather data and learn exactly what impact your program has over time.
Using that data, make whatever adjustments are needed to fine-tune your monitoring processes. After that, you should have enough information to start adding other assets to your PdM program.
Now, if you already have a PdM program in place and want to expand it, I’d still advise taking it one asset at a time. In addition, you probably shouldn’t monitor everything—some assets won’t have much of an impact if they fail, and PdM does have its own costs. Again, it’s all about prioritization.
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How do sensors and actuators work together?
When working in tandem within a given system, actuators receive signals from sensors and perform some kind of task based on that input.
What industries can use IIoT sensors?
Any industry that uses or maintains equipment can make use of IIoT sensors. A few of them include agriculture, manufacturing, and retail.
How are sensors used in predictive maintenance?
Predictive maintenance (PdM) typically uses data from sensors that monitor various conditions on equipment. Algorithms analyze data to predict maintenance.
What are the up and coming IIoT projects in the near future?
The most exciting IIoT projects on the horizon are for maintenance and training tasks and improving energy management with AR.
What do I need to get started for a predictive maintenance (PdM) program?
We talk a lot about planning in implementing maintenance strategies, and predictive maintenance (PdM) programs are no different.
How can my facility use acoustic analysis?
Acoustic analysis has fewer applications than PdM-tool vibration analysis, but what it lacks in breadth of application it makes up for in effectiveness.
What are some industry use cases for vibration analysis?
Amongst the tools in the predictive maintenance (PdM) toolkit, vibration analysis sees tons of use because of its extremely wide variety of applications.
What are the best IIoT projects to start with?
The best Industrial IIoT projects to start with are small ones that meet a specific business need. Once successful, you can increase the size and scope.
How much does deploying IIoT at my business cost?
Industry experts say that deploying an Industrial Internet of Things (IIoT) will cost a minimum of $50,000 or roughly 10 percent of your information technology budget over three years.
What are the benefits of IIoT?
Early implementers of the Industrial Internet of Things (IIoT) have reported better protection of assets, and raised levels of reliability and performance.
What are barriers to IIoT adoption?
The top five barriers to IIoT adoption are cybersecurity issues, a lack of standardization, an installed legacy system, high upfront investment, and a lack of skilled workers
What is prescriptive maintenance and how does it differ from predictive maintenance?
Prescriptive maintenance, is a maintenance concept that analyzes an equipment’s condition to create specialized recommendations to reduce operational risks.
What’s the easiest way to start a predictive maintenance program?
Start with your most critical piece of equipment, track information related to failures, and set up alerts to generate work orders to prevent breakdowns.
What are the biggest problems IIoT could solve for maintenance departments?
Each of these challenges can be alleviated through proper application of IIoT technology, so let’s run through each one starting from helping managing cost.
Will Industrial Internet of Things (IIoT) replace SCADA?
If it does happen, it will probably take a long while, mainly because it would involve uprooting one well-established system in favor of installing another.
What is machine learning and how does machine learning work with predictive maintenance?
Machine learning allows for more intelligent ways of processing data to predict when an asset will require maintenance.
What is the difference between Industry 3.0 and Industry 4.0?
In terms of the words themselves, Industry 4.0 refers to the fourth industrial revolution. The term was coined in 2011 to represent the role that cyber-physical systems (CPS), cloud computing, and IIoT (industrial internet of things) will have on manufacturing processes.
How do I incorporate predictive maintenance without sensors?
Almost by definition, predictive maintenance uses sensors, but the core principle of PdM doesn’t necessarily depend on them.
What are common use cases for using a mileage sensor in predictive maintenance?
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One use case is power failure detection which can create significant downtime losses, and immediate notification can help minimize larger problems.
What are the most common types of IIoT sensors available?
Dozens of sensors are already available to monitor, track, and report on critical aspects of your operations with more under development each day.
What are common use cases for using a vibration sensor in predictive maintenance?
Vibration often signals a potential problem within production facilities that can result in future breakdowns or shorter equipment lifespans.
What are common use cases for using a pressure sensor in predictive maintenance?
Pressure sensors alert maintenance teams when the pressure in a certain tank or piece of equipment falls outside of a specified level,
What is the difference between IoT and IIoT?
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What are common use cases for using a temperature sensor in predictive maintenance?
Most equipment don’t fare too well when temperatures get too high or too low, so even using a simple thermometer can be useful for detecting issues.
How do you improve operations with IoT and predictive maintenance?
The problem with PM is it’s based on the assumption that equipment failures occur on a schedule. The reality is that only 18% of assets fail based on age.
What’s the association between IoT and predictive maintenance?
Using interconnected technology allows us to network cameras and sensors easily with existing computer systems, creating automatic maintenance events.
What are some failure prediction models in predictive maintenance?
With predictive maintenance (PdM), it's understanding an asset's most probable failure modes and monitoring those conditions.
How do you apply continuous improvement to maintenance?
If you’re not focused on continuous improvement each and every day, it won’t be long before you’ll be wasting a significant amount of time and money.
What is the difference between predictive and preventive maintenance?
Although predictive maintenance is similar to preventive maintenance, this activity requires particular preset conditions.
What is level of repair analysis (LORA)?
Without getting too technical, level of repair analysis, or LORA, is a process used to determine when and where an asset should be repaired.