In a context where operating costs are constantly rising and supply chains are facing uncertainties, industries are under pressure to optimize their resources. Given this scenario, there is a need to review maintenance strategies to maximize operational efficiency.
Traditionally, many companies have used corrective maintenance, which involves intervention only when equipment fails or exhibits poor performance. This approach may seem simple, but it is often costly and causes unwanted downtime.
Recent studies by Deloitte have revealed that implementing predictive maintenance can offer significant advantages:
- Increased productivity: up to 25% compared to traditional methods.
- Decrease in failures: reduction of up to 70% in unexpected breakdowns.
- Cost savings: up to 25% less in maintenance costs.
Understanding Preventive Maintenance
Preventive maintenance seeks to prevent machine failures before they occur. By scheduling regular inspections and cleanings, companies can avoid unplanned downtime and better control downtime. This approach not only minimizes the risk of failure, but also optimizes equipment usage.
For example, ABB Electrification Service has developed a Preventive Maintenance Program focused on low and medium voltage equipment. This program aims to anticipate problems and minimize equipment wear, thereby reducing the risk of unplanned downtime. This system is based on the concept of “SWAPS” (see, observe, act, perform, ensure), where maintenance intervals are defined according to the operating environment and the equipment history.
The Innovative Approach to Predictive Maintenance
While preventative maintenance offers benefits, it is not without its limitations. Sometimes, equipment receives more attention than necessary, which can affect the return on investment. This is where predictive maintenance comes in.
This approach uses real-time data to assess the condition of machinery, allowing interventions to be carried out only when necessary. It is based on a series of indicators such as temperatures and equipment performance, thus optimising the timing and manner of maintenance.
ABB Ability™ Asset Manager is a cloud-based tool that makes it easy to monitor and optimize equipment performance. With this solution, companies can check the status of their machinery from anywhere and at any time, resulting in increased reliability and a reduction in the need for unscheduled maintenance.
Benefits of Adopting Predictive and Preventive Maintenance Strategies
Both approaches bring long-term value to companies:
- Improve overall team efficiency.
- Minimize the risk of failures and unplanned stops.
- Reduce maintenance costs.
- Increase operational safety.
- Extend the useful life of the equipment.
Additionally, by continuously monitoring the condition of machinery, companies can anticipate when upgrades or modifications are necessary, ensuring that assets continue to generate a good return on investment throughout their life cycle.
