Predictive maintenance focuses on using calculations and monitoring to predict future trouble spots and correct them when the repairs will cause the least trouble. Instead of replacing or inspecting parts yearly, as in preventative maintenance, predictive maintenance predicts which parts are most likely to fail. Only parts likely to cause a problem in the future are replaced, saving time and money.

Infrared cameras and monitoring systems are used to provide predictive maintenance information. These systems are available for purchase, or you can hire a predictive maintenance expert to monitor your machinery for you. Before you purchase a predictive maintenance system or predictive maintenance consulting, consider the following:

1. Predictive maintenance improves machine reliability and life-span. This is achieved with timely replacements and stress monitoring that catches problems before they spread.

2. Predictive maintenance reduces downtime by detecting problems before they occur and scheduling a replacement at the most convenient time instead of when it breaks.

3. Practicing predictive maintenance is more cost-effective than preventative or problem maintenance because it replaces only what needs to be replaced, and reduces the severity of problems.

Action Steps
The best contacts and resources to help you get it done

Buy a predictive maintenance thermal imaging system to prevent costly problems

Thermal imaging notes heat patterns and temperature changes in objects. This helps find problem spots, like malfunctioning fan belts, circulation systems and lubrication problems. Abnormal temperatures often indicate a problem area in your machinery. Thermal imagers can be hand held or stand-alone units with a variety of settings and varying degrees of automation.

I recommend: Try the thermal imaging systems from Flir Systems, or check out Fluke's selection of thermal imagery equipment.

Hire a consultant to help develop a predictive maintenance system

If you'd rather leave the predictive maintenance work to a professional, you can hire a consultant or just ask for predictive maintenance advice. Consultants can create and maintain a predictive maintenance plan for you, leaving you free to concentrate on running your business.

I recommend: Consult Peterson Predictive Maintenance or ask Sulzer Pumps for predictive maintenance advice.

Set up an in-house predictive maintenance plan

If you've never set up a predictive maintenance plan before, chances are you'll need help. Some companies will work with you to design, implement and maintain a comprehensive predictive maintenance plan in-house. This is often the best and most cost-effective long-term solution to your predictive maintenance needs.

I recommend: Develop an in-house plan with Timken. EnVibe is another in-house predictive maintenance provider.

Tips & Tactics

Helpful advice for making the most of this Guide

• •  You can practice predictive maintenance without expensive equipment and consulting. While a hand held thermal imager is helpful, veteran knowledge of problem areas and approximate product life cycle can help you identify possible problems before they start, without complicated tools. You can often save money and time by checking systems over yourself.