Predictive maintenance (PdM) is the practice of discovering when machines will fail and performing maintenance at a cadence that is optimized for the asset.
Maintenance and reliability teams implement PdM in several steps:
- Screening for asset conditions with the right tools
- Training teams to execute PdM techniques
- Summarizing asset health with a Computerized Maintenance Management System (CMMS)
- Sharing results with stakeholders.
What is Predictive Maintenance Software?
Predictive maintenance software taps into data from condition monitoring, SCADA systems, or other sources and prescribes when maintenance should be performed on assets. The best predictive maintenance software makes PdM achievable in less time and with fewer resources than conventional methods.
Predictive Maintenance Software for Making Sense of Condition Monitoring Data
Condition monitoring with innovative predictive maintenance technology like wireless vibration sensors is a key component in any data-driven maintenance plan. Condition monitoring IoT devices gather a wealth of asset health data that can be transmitted in real-time for immediate action and/or stored for long term analysis and planning.
You can think of predictive maintenance software as the “brains” of condition monitoring. Predictive maintenance software takes all of that data gathered by your sensors and makes that data usable, enabling you keep an accurate pulse on the real-time condition of your machines and pinpoint the areas that require attention. Predictive maintenance software can also measure asset availability, and even predict when a failure might occur. This greatly reduces the number of maintenance tasks your team must carry out and frees them up focus on the activities that matter most.
Connecting Predictive Maintenance Software with Your CMMS to Process Work Orders
Predictive maintenance software separates assets into different classes, where you can set the accepted thresholds for various types of monitoring, such as vibration or temperature monitoring. Once you input the parameters, the imported readings are displayed as color-coded diagrams, showing when the data was taken and what values were obtained for each asset.
Predictive tools can detect failure codes for heavy-duty parts, such as:
- Normal wear and tear
- Low or high-pressure
- Signs of rust/corrosion
- Sudden temperature changes
- Loose joints
- Leaking of liquids
- Clogged pipes
Running PdM software in conjunction with your CMMS is a practical approach to condition monitoring because it adjusts to pre-defined ranges for the key indicators above. This serves as a support system for your maintenance activities, in case you need to calculate the cost of labor, restock spare parts, review floor plan images, or generate custom reports.
If you have a surplus of work orders, you can file those requests on a single dashboard and arrange them by increasing criticality. CMMS software streamlines work orders and upcoming tasks to ensure your technicians can communicate much faster throughout the facility regarding the status of assets. This way, it’s easier to run a successful PM program with all the asset data grouped together.
The Advantages of a Mobile CMMS for Industrial Predictive Maintenance
A mobile CMMS app sends you important alerts for making new work orders on the go, offering features like sending push notifications to your technicians when they perform remote maintenance. This lets you save records of machine runtime, service requests, and inventory transactions on a touchscreen interface. Leading CMMS apps like Fluke Mobile, the eMaint app, allow you to do all this work offline and sync to a network when available.
Another facet of a PM app are inspections, where you complete tangential tasks to pass regulations or obtain certifications through your documents. Some apps have an option to scan barcodes, which is used to search for equipment, and generate a work order from there. In the field, you can issue a service request to approve of technicians who need authorization to start a PM assignment.
To count items on warehouse shelves, you could enter a purchase order using the bar code and have someone add the parts received. A CMMS app eliminates any paperwork filing and assures a faster turnaround, due to shorter travel times for your field technicians.
How a CMMS Lets You Take Corrective Action to Stamp Out Failures
Leading CMMS software can be plugged into a network of integrated systems, allowing you to identify emerging trends and take corrective measures to resolve ongoing problems that eventually lead to downtime.
API Connection
API connections supply a lot of dynamic use cases for both PM and EAM, such as tracking the number of aftermarket purchases.
SCADA Systems
SCADA systems are industrial systems for controlling remote operations to survey industrial processes. SCADA technology captures OT data from sensors placed on motors, valves, or pumps, and can be set to react depending on the severity of incidents, such as by shutting off the machine.
BMS Systems
To handle building efficiency, you can tap into BMS capabilities that reduce operational costs and provide comfort/safety to your employees. Joining one to a CMMS will increase the visualization of smart solutions like HVAC, security, and server rooms, so you know when to call for a specialist.
ERP Integration
For enterprises to keep tabs on their building assets, it would benefit them to install an ERP package that automates CRM, project management, and other financials. While a CMMS has work order data, it can be moved to an ERP system for accessing overlapping functions in asset monitoring.
Predictive maintenance software, best represented by modern CMMS tools, prepares you to enact a maintenance plan that reduces downtime, save costs, and increases your ROI.