Usually, maintenance is performed based on two factors first is when asset failure has occurred and second is scheduled maintenance. In both cases, asset maintenance is done when the asset is in good condition or when it is too late. This is where condition-based monitoring maintenance comes into play.
This maintenance is proactive, and maintenance is given to assets when it is required. For this purpose, assets are inspected regularly, several asset tracking techniques are used such as IoT. It helps in providing real-time information and managers can utilize assets to their fullest extent. In this blog, we will know what the tips for condition-based monitoring maintenance are and why this maintenance is important! So, let us begin!
What Is the Importance of Condition-Based Monitoring Maintenance?
Monitoring based on condition in maintenance focuses on the prevention of downtime, asset failures, and unneeded practices by monitoring the health of the asset to determine which maintenance tasks need to be carried out and at what time.
According to Markets and Markets, “The global machine condition monitoring market size is anticipated to grow from USD 2.8 billion in 2022 to USD 4.0 billion by 2027, at a CAGR of 7.8% from 2022 to 2027."
Condition-based monitoring stipulates that maintenance is only done when certain thresholds have been achieved or indicators indicate indications of a decrease in performance or imminent failure.
Traditionally, monitoring machines for these indicators and thresholds include non-invasive measurements and visual inspections, as well as testing schedules and performance data and, are carried out at pre-determined or set intervals.
Condition-based monitoring is a different approach. It looks at possible failure mechanisms and their indicators, then it monitors for the signs of those.
Common forms of condition-based monitoring are vibration analysis, oil analysis, and temperature monitoring. The data is collected in real-time through sensors, offering continuous methods of checking and monitoring the health of an asset.
The data is beneficial not only for the maintenance team but also for the operations team and fleet managers too.
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The purpose of condition-based maintenance is to detect upcoming equipment malfunctions so that maintenance can be planned to be performed when it is needed and not prior to.
This is a part of the distinction between predictive maintenance and preventive maintenance.
What Are the Important Tips for Condition-Based Monitoring Maintenance?
Below we have given tips for condition-based monitoring maintenance:
1. Parameters You Want to Measure
It is very important to know which kind of machines you want to measure and what parameters you want to measure about the specific machine.
For measuring parameters several techniques are used such as usual asset performance, oil analysis, machine vibration, smoke coming out of the machine, heating, and so on.
2. Establish Beginning Point
While starting a machine you need to collect data on the machine so that you know the limits of each machine individually. Establishing a starting point & collecting valuable data will let you know when the machine exceeds its limit.
It will be helpful in running the machine smartly so that machine sudden breakdown is avoided, and asset performance is maximized.
3. Set Alerts & Notifications
When the machine is not working as per expectations and parameters are matching then the system should alert the maintenance team. So that they can check and adjust alerts & notifications.
Condition maintenance monitoring system provides this feature. This process should be continued until maintenance managers reach a decision about setting a level for asset parameters.
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4. Maintenance Must Not Be Skipped
As we know there are assets in abundance so sometimes maintenance of assets is skipped. However, it can be dangerous for businesses as a hindrance to daily operation can occur.
Moreover, it can lead to sudden equipment failure which will increase maintenance costs and employees’ safety will be jeopardized. Thus, maintenance must not be skipped.
5. Invest in maintenance management software
Investing in maintenance management software such as CMMS software can drastically reduce your workload. For instance, you can easily schedule maintenance for each asset.
You can create a checklist for each work order. Maintenance managers can check costs incurred in each work order. Other than that, you can get maintenance reports within a few clicks with CMMS software.
6. Verify All These Aspects
Absolutely no part of this will work without help from anyone else, except if you check the status of your machinery and practice it frequently. Using all these practices is essential so that the effectiveness of the practice can be seen in asset performance.
So, these were the main tips for condition-based monitoring maintenance. However, it is not easy to implement. Small-size organizations and startups can utilize other proactive maintenance which is easy to implement.
Big size organizations can utilize condition monitoring maintenance, especially those organizations that cannot bear asset downtime, and decreased asset performance but it is costly as well. But once it is implemented it can provide great results.
Asset Infinity provides CMMS software with an asset management mobile application that helps organizations in scheduling maintenance easily.
With this software, you can keep track of each work order and avoid unexpected equipment breakdowns easily. Want to try it yourself? Schedule a demo now.
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Frequently Asked Questions (FAQs)
Q.1 - What Are the Drawbacks of Condition-Based Monitoring Maintenance?
It is not easy to implement as it needs a maintenance team on standby and planning is required. Furthermore, the maintenance team must be skilled & highly trained. It is costly as the maintenance team requires lots of inventory.
Q.2 - What Are the Other Types of Maintenance?
All maintenance types can be categorized into proactive maintenance and reactive maintenance. When maintenance is given before asset failure is proactive, and maintenance after asset failure is reactive maintenance. Proactive maintenance types are preventive maintenance, predictive maintenance, condition monitoring, etc. Reactive maintenance types are emergency maintenance, corrective maintenance, etc.
Q.3 - What Are the Asset Tracking Techniques That Are Helpful to Business?
There are several types of asset tracking techniques available in the market such as Barcode, QR Code, RFID, GPS, BLE, IoT, NFC, etc. Some of these asset tracking technologies are costly and some are cost-effective. Some provide real-time information, and some are effective to use inside the premises of the organization.