Proactive Maintenance

What Is Proactive Maintenance?

Proactive maintenance focuses on anticipating and managing machine failures before they occur. Proactive maintenance requires determining root causes of failure that you can eliminate, identifying potential failure locations, and avoiding breakdowns caused by deteriorating equipment conditions. After you identify critical locations, you can leverage hand tools for vibration or temperature analysis on a regular basis to help determine the optimal maintenance strategy.

Proactive Maintenance Plan

With a solid plan for proactive maintenance in place, you’ll get back every penny you invest and more. By investigating and resolving potential failures before they occur and being able to decide when preventive or predictive maintenance makes sense, you’ll extend the uptime and life of your assets and minimize the need for major repairs. Your assets will work harder for you, boosting their contribution to earnings, without downtime and unexpected failures. 

With a solid plan for proactive maintenance in place, you’ll get back every penny you invest and more. By investigating and resolving potential failures before they occur and being able to decide when preventive or predictive maintenance makes sense, you’ll extend the uptime and life of your assets and minimize the need for major repairs. Your assets will work harder for you, boosting their contribution to earnings, without downtime and unexpected failures. 

Vibration Severity Chart- 10816 Pdfhttps://drive.google.com/drive/u/0/my-drive

Cost saving calculation by Condition Monitoring Program

Cost saving calculation by the work orders generated by Condition Monitoring
A: Cost If any damage occures  without warning: (If OCM doesnot predict)	Downtime * Cost of Downtime/hr + Direct maintenance cost (unplanned & Unscheduled) + Potential damages
B: Actual cost of repair:  (If OCM predict)	Downtime (if any - should be fixed in scheduled shutdown) * Cost of Downtime/hr + direct maintenance cost (planned & scheduled) + Damages(= 0)
A- B	Cost of avoidance (Cost Saving)
Example:
If a coupling damage occurs without any prediction. The cost saving (cost of avoidance) can be calculated as mentioned below.
A: Cost If any damage occures  without warning: (If OCM doesnot predict)	Downtime * Cost of Downtime/hr + Direct maintenance cost (unplanned & Unscheduled) + Potential damages
Downtime* cost of downtime/hr= 8 hours (say) * 0 (As standby machine is available)=0 USD
Direct Maintenance cost ( cost of the coupling and labour hours (say 4 hrs) for replacing the coupling) =3000USD
Potential Damages= Cost of damaged bearings and the seals replaced during this opportunity and the extra labour cost (4hrs)= 4000USD
(associated damages since it is not predicted at an earlier stage)
Total Cost (A)= 0+3000+4000= 7000 USD
B: Actual cost of repair:  (If OCM predict)	Downtime (if any - should be fixed in scheduled shutdown) * Cost of Downtime/hr + direct maintenance cost (planned & scheduled) + Damages(= 0)
Downtime* cost of downtime/hr= 4 hours (say since only coupling is damaged) * 0 (As standby machine is available)=0 USD
Direct Maintenance cost (material cost and labour hours (say 4 hrs) for replacing the coupling only) =3000 USD
Damages= (No other damage occur since coupling damage is predicted before any further failure of other components)= 0 USD
Total Cost (B)= 0+3000+0= 3000 USD
Cost of avoidance (Cost Saving)= A-B= 7000-3000= 4000 USD