4. Predictive maintenance
Predictive maintenance is the most efficient way to diagnose the potential for equipment failure. It uses condition-based monitoring to assess equipment performance in real time, taking measurements of relevant operating parameters to compare with known equipment fatigue profiles.
While condition-based monitoring is not full predictive monitoring, it is a step to enable the use of data that can be used to keep a system running as long as possible before shutting down for maintenance, thereby decreasing repair cycle intervals. It increases the equipment throughput, reducing overhead costs per part produced, and it reduces costs from increased purchase and installation of unneeded equipment repair.
Though the best-in-class approach, predictive maintenance will take time to implement and requires an upfront investment in sensors, monitoring, analytic software and operator training before rolling out.