13 - Predictive maintenance/ condition monitoring

Abstract

Most equipment fails in a random pattern. Given the random nature of most failures, there must be a condition monitoring (CM) program that routinely detects onset of failure to enable decision making about avoiding or managing those failures. Run to failure may be acceptable when the consequence of the failure is minimal, or when the cost of data collection is greater than the potential cost of the failure. For most equipment this is not the case, and so knowing the condition of the equipment can lead to a better position to make good business decisions. CM is an essential tool for manufacturing excellence. The chapter shows that the more the CM program is comprehensive, the lower the maintenance costs is. A critical requirement for any program is to have a good work management process for planning and scheduling the work that is identified through CM, as well as scheduling and complying with the CM. CM should also be included in the commissioning process to verify proper installation as well as early detection and mitigation of problems to minimize the risk and consequence of failure.