Predictive Maintenance Software
Predictive maintenance software is a tool designed to help businesses analyze their in-service equipment in order to determine the most appropriate time and the level of maintenance to be implemented.
The predictive maintenance process, also referred to as PdM or condition-based maintenance, is an increasingly common maintenance strategy that involves both equipment condition monitoring and performance monitoring approaches of in-service equipment. This means predictive maintenance can be conducted during the regular operation of any piece of equipment. The goal of this strategy is to minimize the chances of equipment breakdown, streamline the workflows of the maintenance team as well as to reduce overall maintenance costs by predicting potential equipment failure based on a combination of real-time data and a specific set of factors and parameters.
Once forecasts or predictions have been made, manufacturers can use the data to take the necessary steps in preventing the failure with more conventional maintenance operations and techniques, such as corrective or scheduled maintenance processes. Predictive maintenance is a more cost-effective approach to asset management at any scale, especially with the other option is the highly inefficient reactive maintenance process. Good predictive maintenance software effectively combines the power of data analytics and robust equipment monitoring solutions to evaluate key asset performance and predict potential failures of in-service equipment. With this category of maintenance software, businesses will have the ability to develop proactive and information-based maintenance strategies.
Predictive maintenance software is designed to facilitate the asset management process by using real-time monitoring solutions in order to keep track of the equipment’s performance over time. A predictive maintenance system monitors equipment by using tools like gauges and sensors, which are capable of detecting changes in equipment temperature, sound or vibrations. The data that is captured by such tools are then integrated into the system so it can perform a comprehensive analysis to evaluate equipment performance and figure out whether or not preventive maintenance, repairs or even a complete replacement of the equipment will be necessary.
Implementing a PdM approach involves using a number of technologies that support condition monitoring strategies, such as vibrational analysis, infrared thermography and acoustic monitoring. Vibrational or vibration analysis measures the level of vibration produced by any high-speed rotating machinery such as turbines, compressors, engines, gearboxes, generators, etc. Asset managers and technicians will often use a handheld device or small real-time sensors attached to the equipment to closely monitor vibrations.
Vibrational sensors and other similar technologies are designed to monitor equipment function and performance by measuring its vibrations while in service. For instance, when a generator is at optimal or peak performance, it usually emits a specific and fairly consistent vibrational rhythm. Any change to the vibrations may signal a potential issue, triggering a closer examination of the equipment through a preventive maintenance process, which is a whole separate process from predictive maintenance. This is to ensure any potential issues are taken care of before they become a serious problem that could result in equipment downtime.
When the sensors or the handheld devices detect a change in the vibrational rhythm of a particular piece of equipment, the information is collected and analyzed by the predictive maintenance software, which then initiates the necessary work orders while also scheduling maintenance. With constant vibrational monitoring and analysis, an experienced asset manager or technician can easily and accurately match vibration readings against known patterns that signal potential failure, effectively avoiding serious or crippling equipment failures down the road.
Another strategy that can be used in conjunction with the right predictive maintenance solution is acoustic monitoring. This approach involves utilizing acoustic analysis technology to detect sound changes at sonic and ultrasonic levels. With this technology and this condition monitoring strategy combined, maintenance teams and technicians can easily detect any sound emitted by their machinery, whether it’s caused by gas, liquid or vacuum leaks. Comparing sonic and ultrasonic technology, the latter has far more applications than the former when it comes to condition monitoring. While ultrasonic is more expensive, it is a far more reliable and useful technology for predictive maintenance.
Infrared thermography is all about measuring and monitoring equipment temperature. This is a non-intrusive testing and monitoring technology that is commonly implemented by businesses and organizations in their predictive maintenance processes. It involves using infrared cameras pointed at specific areas of the machinery. Maintenance teams and personnel can refer to the display to detect temperatures within the equipment that are above normal. Key components that are worn out within a piece of equipment, malfunctioning circuits, etc.—all these tend to have a significant rise in temperature, which is then represented by a heat spot on the thermal imaging device.
Through a robust predictive maintenance software solution, infrared thermography can help maintenance teams and technicians find hotspots in their equipment earlier so they can immediately take action to remedy the issue before it becomes a larger and more costly problem. Infrared thermography or thermal imaging is a versatile technology that can be applied to a wide range of equipment, machinery and infrastructural projects. This is a highly effective solution for temperature-based condition monitoring.
Oil analysis is another condition monitoring strategy that can be very efficient when used for predictive maintenance purposes. You can effectively use your predictive maintenance software to capture data and analyze the oil conditions of your equipment or machinery. By using oil analysis for condition monitoring, you will have the ability to examine the oil from your equipment for contaminants. It allows you to measure the level of viscosity, moisture/water and particles in the oil, as well as determine the acid level or base number. The key with the oil analysis strategy is to use the initial test result as a baseline for any new equipment or machinery that has recently gone through maintenance.
There are many advantages to implementing the right predictive maintenance software to assist your maintenance personnel, especially if your whole business revolves around the performance and well-being of your machinery where even a relatively short downtime can potentially cost your entire company a lot of money.
One of the biggest benefits of predictive maintenance solutions is cost reduction. By implementing a good PdM strategy and using the right tools and resources, you can effectively cut down on costs. This is especially true for companies in industries where constantly buying brand new equipment or even replacement parts can be cost-prohibitive. If you’re in an operation where running machines and equipment until they fail or breakdown simply isn’t fiscally acceptable, then using a predictive maintenance solution can help ensure that all your equipment is in good health and running smoothly without any additional cost.
Predictive maintenance software works by scanning relevant equipment data, allowing it to detect performance changes in real time. This is an excellent condition monitoring strategy that helps ensure cost-effective maintenance process; i.e., equipment maintenance is only initiated or prompted when a reasonable change in its performance is detected. Maintenance personnel don’t have to shut down the equipment just to replace parts that are still in good condition and usable, thus eliminating delays to service. Different sensors can be used with the software to capture and analyze data based on temperature, pressure, humidity and energy consumption, just to mention a few.
PdM software also helps in reducing equipment failures and unscheduled downtime. A scheduled maintenance for a piece of equipment may cause a delay to service, that’s for sure. However, that is nothing compared to unexpected downtime due to equipment failure. With unexpected or unscheduled downtime, you have no idea when the machine or equipment will go back to service, especially when your technicians and maintenance personnel are still scrambling to figure out what went wrong. With a PdM solution, you can perform scheduled maintenance on a regular basis to anticipate such failures so your business operation doesn’t suffer from the uncertainty of an unexpected equipment breakdown.
Moreover, implementing the right predictive maintenance software also helps extend the life expectancy of your equipment. When you integrate predictive maintenance with your overall asset management strategy, it doesn’t help minimize your maintenance costs. This approach helps improve the performance of your equipment, maximizes its uptime and most crucially increases its overall life. The PdM software works to monitor the condition of every piece of equipment in service for your company by using data fed by sensors and other pieces of technology that you might have to capture temperature readings, vibrations and even sound.
Some of the other benefits of implementing predictive maintenance tools include maintaining industry compliance rules and regulations, improved productivity, better analysis of real maintenance costs and reduced paperwork.
Predictive maintenance software captures and monitors true equipment conditions in real time to provide equipment managers and maintenance teams with the most accurate information possible, which helps them make data-driven decisions. This category of software can be integrated with other systems such as enterprise asset management (EAM), preventive maintenance and asset performance management software, among others.
PdM software can be available as a best-in-class standalone solution or as part of a much larger and more comprehensive platform such EAM or CMMS, which stand for computerized maintenance management system. A PdM solution is equipped with a few core features such as maintenance scheduling, asset management and purchasing, work order management, real-time condition monitoring, performance analytics and reporting, failure mode and effects analysis (FMEA), as well as automated alerts and notifications.
