Improving operations with predictive maintenance
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The document emphasizes the inefficiencies in traditional preventive maintenance practices, highlighting that many organizations do not utilize predictive maintenance effectively. It introduces condition-based maintenance (CBM) as a solution that leverages IoT technology to monitor asset conditions, ultimately optimizing maintenance efforts and reducing costs significantly. The statistics presented suggest that adopting CBM can lead to substantial reductions in maintenance costs and unplanned downtime.
Improving operations with predictive maintenance
- 1. © Copyright IBM Corporation 2016. IBM, the IBM logo, and ibm.com are trademarks of International Business Machines Corp., registered in many jurisdictions worldwide. Other product and service names might be trademarks of IBM or other companies. A current list of IBM trademarks is available on the Web at “Copyright and trademark information” at www.ibm.com/legal/copytrade. 1 Source: Oniqua Enterprise Analytics, Reducing the Cost of Preventative Maintenance, http://www.plant-maintenance.com/articles/PMCostReduction.pdf 2 Source: T.A. Cook, Maintenance Efficiency Report 2013, August 2013. http://uk.tacook.com/fileadmin/files/3_Studies/Studies/2013/ T.A._Cook_Maintenance_Efficiency_Report_2013_En.pdf?tracked=1 3 Source: ARC view, Optimize Asset Performance with Industrial IoT and Analytics, August 2015 http://www-01.ibm.com/common/ssi/cgi-bin/ssialias?subtype= WH&infotype=SA&htmlfid=WWL12350USEN&attachment=WWL12350USEN.PDF 4 Source: Enterprise Asset Management and Field Service Management, ARC Advisory Group, 04/17/2015. http://www.arcweb.com/market-studies/pages/enterprise-asset-management.aspx 5 Source: McKinsey https://www.mckinsey.de/sites/mck_files/files/unlocking_the_potential_of_the_internet_of_things_full_report.pdf 6 Source: Fortune http://fortune.com/2015/07/22/mckinsey-internet-of-things/ 7 Source: G.P. Sullivan, R. Pugh, A.P. Melendez and W.D. Hunt, “Operations & Maintenance Best Practices: A Guide to Achieving Operational Efficiency, Release 3.0,” Pacific Northwest National Laboratory, U.S. Department of Energy, August 2010. 8 Source: IDCON Inc., Optimize your Preventive Maintenance, http://www.idcon.com/resource-library/articles/preventive-maintenance/528-optimize-preventive-maintenance.html Learn more about how CBM can help you maximize uptime, visit: http://ibm.co/asset-mgt A full 40%of organizations are not using any form of predictive maintenance.4 50% 4 Total spend on preventive maintenance can be reduced by up to 23%of organizations that are using predictive maintenance integrate work order systems.4 Only For example, on one oil rig 99%of data collected from sensor-enabled assets went unused. 5 30%of preventive maintenance activities are carried out too frequently1 45%of all maintenance efforts are ineffective2 Most companies are aware of waste in their preventive maintenance efforts, but aren't quite sure how to eliminate it. Traditional preventive maintenance embraces a time based approach. This consumes unnecessary resources and may actually cause failure by disrupting the equilibrium of stable assets. 3 How do you know where to spend your time, money and resources? Your machines are talking. Are you listening? Condition-based maintenance (CBM) is a discipline that uses the Internet of Things to monitor asset conditions and trigger preventive maintenance actions. This can help you predict and prevent unplanned downtime. With CBM you can: Listen to your machines! The results speak for themselves. By implementing CBM best practices: and yet... Monitor and analyze asset health data, both historical and real-time Intervene at the right time, before assets go down Prioritize and optimize resources Listen to your machines! Are your preventive maintenance efforts wrenching away precious resources? Time to listen to your machines. Eliminate up to of breakdowns7 70%25% 6 Reduce maintenance costs by up to 50% 5 Reduce downtime by up to 12% 7 Reduce scheduled repairs by up to 50% 6 Cut unplanned outages by up to 3-5%5 Reduce capital investment by 50% to 70% Total preventative maintenance hours can be reduced by8 40%of preventive maintenance costs are spent on assets with negligible affect on uptime failure1 Only 18%of assets have an age related failure pattern3 82%of asset failures appear random3