There is no easy solution for high-cost maintenance work. It takes a lot of time and energy to choose predictive maintenance methods, so as to provide the most economical and effective measures to evaluate the operation state of key factory systems, establish program plans, create a feasible data base and a benchmark value. The actual time and manpower required will vary with the size of the factory and the complexity of the process system. For a small company, the time required to design a feasible plan is aboutthreeMan-month Generally speaking, for integrated processing plants, this initial effort takes as long as15The time of the year. Is the benefit we are trying to get worth the effort? In almost every case, the answer is absolutely yes. common10There are three steps to help you implement a successful overall plant predictive maintenance plan:

1.Determine the existing maintenance costThe most difficult step in the preliminary work of predictive maintenance plan is to determine the actual maintenance cost. Most factories do not track all the controllable costs related to maintenance work. In most cases, the cost accounting function limits the cost tracking of actual manpower and materials used to maintain factory equipment. They do not include the impact of maintenance work on availability, production capacity, operating costs, product quality and a large number of other factors that can limit the efficiency of the factory. In addition to maintenance labor and material costs, your assessment should also include all maintenance-related costs related to delay, operation below production capacity, overtime allowance and product quality. Your assessment should also include compliance with safety and environmental regulations. In some cases, the accounting department can help to complete a very approximate estimate of the maintenance cost. Explain to them the reasons for your request and ask them to help quantify the historical factory cost. The cost history obtained at this moment is of great significance. Initially, it can be used for cost-profit analysis and to prove the rationality of your predictive maintenance plan. Later, this data set will become the basis for quantifying the actual benefits obtained by the plan. Factories should not neglect the implementation of this part of the plan. The accuracy and completeness of this data set is crucial to the long-term success of your plan. Most projects that fail in the first two years after implementation are directly related to the lack of quantitative results.

2.Select predictive systems and suppliersAnother major factor that caused the plan to fail was the choice of the wrong predictive technology or the supplier who could not provide long-term plan support. Attention must be paid to this selection process. An overall plant predictive maintenance plan must use a combination of monitoring and diagnostic techniques to achieve the benefits of * * * * * *. No single technology (such as thermal imaging and vibration monitoring) can provide all the capabilities needed to evaluate key factory processes and systems. What technology combination is * * * * * for your factory? Unfortunately, there is no simple answer to this question. The forecast requirements of each factory are different. Your plan should at least include:(1)Main operation process analysis;(2)Thermal imaging;(3)Process parameters, and(4)Visual inspection. Lubricating oil and wear particle analysis (friction analysis) should be carried out only if the additional information obtained proves that it is worth the cost. Care should be taken when selecting forecasting systems and suppliers. When selecting predictive maintenance system, at least the following questions should be considered:2a.Can fully meet your specific needs. No predictive maintenance system is perfect. Each system has its own advantages and disadvantages. For example, many vibration monitoring systems can't handle lower than.600 RPMMachine speed, or can't use a variety of sensors. These two restrictions will reduce the benefits you can get from your plan. Determine the specific requirements of your system and ensure that the selected system will meet all these requirements.b.The stability of the system and suppliers should regard the predictive maintenance plan as the life of the plant continuity improvement plan. Therefore, the system you choose for the factory must be effective for a long time. The competition in the field of predictive maintenance is fierce. Many early suppliers either disappeared or were merged by other companies, or their system structures were constantly changed. All these factors will affect the long-term state of your plan. Your assessment should include:•Financial resources of suppliers;•Product development history;•Technical support;•Existing customer base.

threeTraining requirements and supportMost predictive maintenance vendors provide some level of training. However, most training programs are oriented to the use of specific systems (that is, the use of software and instruments), rather than the comprehensive utilization of maintenance technology. For reference, I am at30I have used all predictive maintenance technologies for many years, and now I am still learning something new every day. Many suppliers can provide technical training that can support your predictive maintenance plan. However, you should carefully evaluate the advantages of their training courses before choosing them as training support. Generally speaking, independent training companies that are not associated with equipment manufacturers can provide high-quality training in an impartial manner.

4.Get management supportLack of total factory investment or company management to provide the resources needed to implement and maintain a plan is the most important reason for the failure of predictive maintenance plan. There are several reasons for the lack of long-term investment. But in most cases, it comes from the lack of planning and rationality evaluation in the process of planning preparation. The management must know the real cost and potential profit of the plan before it is implemented. After the implementation, the management must keep abreast of the progress of the plan and the actual benefits provided by the plan. Therefore, it is essential to design a feasible method to quantify the actual results of the plan and convey the development status of the plan to all key managers. Management support should include the implementation of a form of maintenance plan, a feasible information management plan and skills training for skilled workers, so as to obtain the benefits from predictive maintenance. Predictive planning can provide the motivation for maintenance activities, but without correct planning and adequate maintenance skills, the full benefits of maintenance planning will not be obtained. The information management plan has two functions:(1)Maintain equipment history;(2)Track the benefits from the plan.

5.Design a program planA definite program plan containing all the activities required for the overall plant predictive maintenance plan must be designed before your plan is implemented. The program plan shall include:•Specific planning scope;three•Objectives and objects;•Methods used to implement, maintain and evaluate the plan. The plan should also include a specific rate of return on investment that can be used to measure the success of the plan.(ROI)Standard.

6.professionalA major part of the successful plan is a group of full-time professionals. Plans cannot be carried out and maintained by part-time workers. Although there are predictive maintenance techniques for program planning, it is absolutely indispensable to monitor key equipment parameters regularly. Most plans completed by part-time workers fail because the activities needed to maintain the plan are delayed or ignored because of the urgent demand for personnel time.

7.Establish accountingThe predictive maintenance team must understand the reasons for implementing the plan and be responsible for the success and failure of the plan. The degree of personnel input is an indispensable requirement for a successful plan. Without this overall investment, the plan will probably fail. The department manager is also responsible for the success of the plan. In most factories, these managers control the capital and human resources in their departments. Without their right to support and invest in the plan, little effect will be achieved.

8.Develop a feasible databaseThe actual benefits obtained from a plan depend on the accuracy and completeness of the database developed for the plan. All predictive maintenance techniques depend on a clear and detailed definition of the key equipment involved in the plan. Database development needs a lot of manpower and time. In a large-scale integrated processing plant, the development of a typical predictive maintenance plan based on microprocessor takes as long as.10The time of the year. Even small factories must invest equally in the process of planning and starting.1-3The time of the year. However, the time spent is worthwhile. The initial investment will greatly reduce the manpower and time required to maintain your plan, and will greatly increase the benefits gained from the implementation of the plan. Most plan failures come from ignoring the steps of database development. Part of the reason is the lack of accurate machine data and the limitation of many predictive maintenance systems. To get * * * * * benefits from your plan, please invest the time and manpower needed to build a complete database.

9.Maintenance planPlease don't leave after the execution phase is completed. The failure of many plans is attributed to the fact that factory personnel did not continue after the development stage. Please follow the plan. Please carry out every arrangement in the program plan. Continuously evaluate the progress of the plan and correct any mistakes or problems that may exist. A successful predictive maintenance plan must be dynamic. Stick to the end.

10.Information transmissionInformation transmission is absolutely necessary for the long-term success of the plan. All successful plans have a very clear information transmission plan, including the transmission of corrective actions identified by the plan, feedback from the manufacturing department, and periodic plan status reports circulating throughout the factory and company management. Determining the rationality of the plan is a never-ending process. Managers and other factory team members must constantly understand the status of the plan and the benefits gained from it. Failure to convey information will seriously reduce the possibility of success of the plan.

  Although it takes great efforts to implement and maintain the overall plant predictive maintenance plan, the benefits from the plan will also be enormous. Predictive maintenance, as a part of the overall plant operation management plan, can reduce the adverse impact of maintenance on availability, product quality and operating profit if it is correctly implemented and maintained. Predictive maintenance can transform maintenance operation from an expensive support function into an important member of the factory that brings profits. Don't expect any simple and quick fixes. Like all valuable things, it takes some effort to get positive results. If you follow these steps, you will establish an overall factory predictive maintenance plan that can provide * * * * * benefits for your factory.