Is Your Predictive Program Working?

The general belief of predictive maintenance is that it is a maintenance tool that uses vibration, infrared or lubricating oils analysis data to prevent catastrophic failure of, and unplanned production downtime caused by equipment failures. Because of this belief, predictive programs are set up with the singular mission of breakdown prevention without any focus, or even thought about, on the overall impact on these programs. While many of these programs have resulted in verifiable and measurable reductions in unscheduled downtime caused by asset breakdowns, they have increased overall maintenance cost and a decrease in overall plant performance.

Several factors have contributed to the negative results of traditional predictive maintenance programs. The fundamental reason that most programs have failed to achieve a marked improvement in overall plant performance is the breakdown mentality that continues to dominate the management philosophy of somr corporations. Because of this attitude, we have failed to perceive the real benefits that a predictive maintenance program can supply and have not recognized the negative impact that this limited application has generated. These plants do not understand that high breakdown rates, as well as maintenance costs are the visible symptom of a much more serious design, buying, production or management problem which cannot be resolved by simply preventing catastrophic failure of critical machinery.
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