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The Step By Step Process To Implement Predictive Maintenance In Your Company


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According to the Predictive Maintenance Report of Market Research Future, the global predictive maintenance market is expected to grow to $6.3 Billion by 2022 from $4 Billion in 2020.

And to no one’s surprised as the major contributors to this growth include the constant increase of emerging technologies and the growing need to reduce maintenance costs, equipment failure, downtime, and production bottlenecks.

To stay competitive, companies need to make improvements in their processes continuously. They need to make sure that the steps that they are implementing are practical and up to date.

One of the best ways to do this is through process improvement by predictive maintenance. When a company takes on a maintenance process improvement project, they look at the entire operation from top to bottom.

This article will guide you through the complete step-by-step predictive maintenance process to make your company’s successful maintenance journey.

The Step By Step Process To Implement Predictive Maintenance

1. Audit

The first thing that will be done is to conduct an audit of all equipment and machines functional in the company. These audits can be done internally and externally for reviewing the functions of the company machines, determining which processes need to be improved.

This audit’s main objective is to clearly and precisely define the goal and scope of the predictive maintenance implementation. Your company needs to identify precisely what you want to predict and how early.

You have to consider all the systems of your company for conducting a thorough audit such as assembly line, brake system, cooling process, heat exchanger, etc. For each of these equipment/machines, you will need to identify the precise maintenance tasks and processes in the coming stages.

Once the audits are completed, a team will be formed to move ahead with the hazard analysis and data collection from all the company resources.

2. Hazard Analysis And Data Collection

Once the work has been completed, another step will be taken towards hazard analysis. In this step, the hazards that currently exist in the company systems will be identified for estimating their unforeseen consequences and analyzing their potential causes.

There can be different types of hazards existing in your system, such as:

  • Biological
  • Chemical
  • Physical
  • Safety
  • Ergonomic
  • Psychosocial 

    Now you can collect all supporting historical and real-time data from company data sources such as back-office files, IoT devices, and employee reviews to understand the machines’ past performance. The failure and maintenance data can enable you to predict the current and future condition of your assets.

When these hazards have been identified, a plan will need to be put in place to eradicate any potential threat that currently exists.

3. System Optimization

This step is aimed to generate and experiment with the system algorithms until all hazards that existed in the entire company system are eliminated. It would help if you found a reliable and efficient software solution to sail you through this process.

Using the system data and advanced machine learning analytics, this state of the art software generates algorithmic planning and optimized processes for your company. These automatically generated processes with optimal maintenance plans and schedules can help your machines to reduce the maintenance duration and frequency considerably.

Overall equipment effectiveness (oee) measure will give you a clear picture to identify the accurate percentage of manufacturing time that is productive for your company. This standard will allow you to finalize the most compatible processes for the maintenance of all your machines.

The predictive maintenance plan is aimed to avoid any unforeseen machine, resources, or workforce necessity to conduct maintenance for failed systems at peak hours. Many-a-times, maintenance procedures require some employees to be sent home. System optimization will allow you to plan ahead and plan better.

4. Communication

After the above steps have been completed, the next step will be to communicate the changes that have been made to all stakeholders. It is essential to do this on time so that everyone understands what is going on.

If an employee does not know that a specific procedure is required, it is essential to let them know. By doing so, everyone will be informed of the procedure and what is needed to perform it. Effective communication will reduce the risk in the workplace preventing any injury while operating hazardous machinery.

You can achieve this by conducting meetings, forums, conferences, and newsletter series to update your workers and staff for all the modernizing technologies that would lessen their manual work and bring efficiency to the system.

5. Training

The last step in this process to implement predictive maintenance is to train your employees. New technology and optimized processes always bring additional benefits to employees, but they should be skilled enough to adapt to these changes.

You can do this by having them learn the procedures and then showing them how to complete the tasks as part of their daily work. Many times this will include video documentation, online sessions, and practical training of the procedures.

Determine all the systems and include all the workers playing even the smallest role in the system. As your business grows, you will likely want to have employees focus on a different group of tasks for your business. This way, you will be able to shift workers during the equipment’s maintenance period.

Concluding Remarks

When you understand each aspect in this step by step process to implement predictive maintenance in your company, you can quickly see how much money you could save in the long run. This type of maintenance is very cost-effective. When your equipment is in good working order, it reduces the number of trips to the repair shop.

It also can save you money on the cost of parts and labor when they break down. By taking advantage of the opportunity that information technology presents, you can improve your company and help your customers have a better experience with your products and services.

We hope this detailed guide will enable you to transform your business with predictive maintenance techniques to help you improvise the in-service equipment with an estimated maintenance procedure.

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