Condition-based maintenance (CBM) is a maintenance strategy that monitors the condition of your equipment to determine the necessary maintenance to perform. Unlike planned maintenance (PM), where maintenance is performed based upon predefined scheduled intervals, the goal of condition-based maintenance is to identify the need for corrective maintenance when it is needed – and not before. Compared to traditional time-based condition monitoring, real-time monitoring involving IoT enabled solutions offer six distinct advantages:
1. Identify Issues Before They Escalate
Even the smallest issue can snowball into a serious problem if it goes unnoticed for too long. Continuous manufacturing processes have any number of single points of failure that can halt production. Not only does real-time condition monitoring allow you to determine areas for improvement, but it can also help manufacturers identify potential problems and take the necessary actions before issues occur, often well in advance of time-based monitoring.
- Sensors track changes in vibration, temperature, oil quality and cleanliness, and then output to detect any issues with corrosion, wear, misalignment, imbalance, or lubrication.
- Service maintenance can automatically be scheduled ahead of time to prevent part failure or system damage.
- Critical outages and unplanned downtime can be avoided by identifying potential equipment failure allowing corrective work to be scheduled during scheduled work outages.
2. Reduce Unplanned Downtime
Run-to-failure might be the simplest maintenance strategy but it is not a recommended strategy. Waiting for something to break, can waste valuable production time, money and potential revenue. A continuous monitoring solution provides a clear picture of their asset’s overall health, greatly minimizing the occurrence of unexpected failures. Coupled with advanced data analytics, real-time condition monitoring can provide a much earlier warning of impending problems allowing for longer lead times for corrective work.
3. Decrease Maintenance Costs
IoT-enabled condition monitoring solutions give you the data to get early notices of failures or avoid a pending failure that if not detected or left unresolved, could become catastrophic and extremely costly to your maintenance budget.
4. Avoid Hazardous or Hard-to-Access Environments
Most time-based condition monitoring techniques require a technician to access equipment under normal operating conditions. As such, safety becomes a primary concern with routine condition monitoring. By deploying IoT sensors, real-time data can be captured and analyzed without exposing employees to workplace hazards.
5. Better Information for Better Decision-Making
Using sensors to collect data could reveal operational inefficiencies that would not be apparent until a catastrophic failure occurs. Receiving as much advance notice on failures or pending failures provides more time for you to make the appropriate decisions on a better asset location, environment adjustments, oil changes, etc.
6. Improve Labor Efficiency
IoT-enabled condition monitoring solutions ensure that work only needs to be scheduled that truly needs to be done. This helps to eliminate the 50% of PM work that has be estimated to be unnecessary, freeing up valuable resources for other value-added tasks.
Two Additional Reasons You Need to Monitor the Condition of Your Oil
Studies show that approximately half of lost machine life is due to mechanical wear and Approximately 80% of mechanical wear is caused by particle contamination in the oil.
It has been estimated that most production organizations lose between 10 and 15% of their plants total maintenance budget each year due to downstream effects of poor lubrication.
To learn more about download our whitepaper Leveraging IOT For Condition-Based Maintenance