Keeping equipment working should be paramount to any organization. It could mean the difference between meeting and missing the order. However, in North America, 55% of all maintenance performed is still reactive. Equipment failure is accepted as the norm – “When it breaks, we’ll fix it.” Equipment failure can be avoided by performing preventive or predictive maintenance so this way of thinking is outdated and can be an expensive mistake. Gradually, maintenance is becoming more advanced and finally moving into the computer age!
What is Condition Based Maintenance
Condition Based Maintenance (CBM) is a maintenance strategy that uses information gathered on the health or condition of an asset to determine when maintenance should be performed. Non-evasive measurements, visual inspections, performance data and tests are performed to detect deteriorating performance or faults before they occur. By performing these condition checks, organizations can extend machine life, increase productivity, and lower maintenance costs.
How Can CBM be Integrated into your Day to Day Maintenance
A CMMS like Maintenance Assistant can be used to schedule calendar based planned maintenance but in this modern, data-intensive age, we can take it to the next level with condition-based maintenance (CBM). And Maintenance Assistant CMMS can help you do just that! It is the ideal tool to manage your reactive, scheduled and predictive maintenance in one central location. Studies have proven that a well-implemented maintenance strategy that utilizes CBM can reduce maintenance costs by 30-40%. CBM is best used on critical assets and is not an organization wide approach so it makes up a subcategory of your maintenance strategy. Critical assets tend to be more expensive and can have a greater effect on production so it makes sense to move from reactive to proactive maintenance.
Three Phases of CBM
How can you introduce CBM into your organization using Maintenance Assistant CMMS?
CBM can be introduced slowly into the organization one critical system at a time. Often, a reliability engineer is required to develop and manage the CBM within an organization but maintenance technicians that have the system experience can be quickly trained on CBM techniques. It requires examining the manufacturers’ recommended maintenance and with repair and performance data from the CMMS to decide the inspection actions that need to be performed and at what interval. When the CBM actions are decided, the reliability engineer can configure the CMMS to trigger when the inspections are due and to proactively create a work order when something is out of spec.
1. Spot Checks – Evaluate the condition of an asset by performing periodic spot checks using portable instruments
1. Create a scheduled maintenance with meter-based triggers based on the condition of the asset. For example, replace the filter when the differential pressure exceeds 20psi.
2. Create your scheduled maintenance with time-based inspections. You can complete inspection rounds on multiple systems using multi asset work orders.
3. Perform the planned inspection when due or record the data using the batch meter reading upload tool.
4. Maintenance Assistant will trigger a preventive work order when conditions exceed the predefined limits. The technician can proactively schedule the repair before the system fails. In the above example, the technician is checking the condition of the Photon Accelerator at a number of different points for various different signs of issue. For example, the oil sample can detect excessive wear by measuring the size and number of particles in the sample.
2. Machine interfaced systems
More expensive equipment can ship with built in diagnostics that self monitor during production. When a parameter is trending out of spec, or when an immanent failure is detected, the system can push this event to a CMMS through the API. For example, the system may trigger a temperature out of spec error when a cooling device fails. The CMMS can be configured to trigger a work order based on this event so the technician can investigate. In Q4 2013, Maintenance Assistant will release its public API so users can connect equipment directly to their CMMS.
Reduce Maintenance Costs
Integrating CBM into your organization can be challenging as it requires advanced training and experience but ultimately it leads to more efficient maintenance. CBM monitors the health of the asset in real-time and gives it the predictive power to increase system reliability and availability while reducing maintenance costs.