The concept of condition monitoring is not new. Workers on the floors of industrial operations have utilized their eyes, ears, and hands to discover issues in their equipment since the birth of the machine age. On the other hand, today’s technology provides for significantly more precise detection of minor variations, allowing for proactive rather than reactive maintenance. A machine-mounted sensor based data driven monitoring system continually examines performance for symptoms of abnormal movement. The analysis findings may be shared anywhere, allowing anybody to look for issue indications in real-time, including floor operators, distant managers, and third-party maintenance contractors. Sophisticated monitoring systems enable real-time identification of minor changes in a machine’s operation. Some of the most critical advantages of condition monitoring are listed below.
Maintenance Costs are Reduced
As provided by firms like ATTAR, the fundamental advantage of condition monitoring is that maintenance expenses are reduced. Although a “repair as it breaks” strategy may save money in the short term, it is always more costly in the long run. Furthermore, faulty machinery can have a ‘ripple effect.’ Other equipment farther down the production line malfunctions, resulting in more losses. The majority of manufacturers claim that concealed internal defects account for 3% of machine downtime. Condition monitoring is a good investment for any manufacturing organization that values dependability since these defects are nearly hard to discover without predictive maintenance procedures.
Extending the life of machinery while reducing unscheduled downtime
Good machinery and high-quality parts are built to survive, and condition monitoring can even assist increase component lifespans and machine lifetime. Renold Gears, for example, argues that repairing gears rather than replacing them may save up to 40% on maintenance expenses while also improving overall performance levels. It demonstrates how condition monitoring may reduce costs not only hidden but also increase total productivity. All process industries strive to reduce unexpected downtime because of the high direct cost of these events and the disruption that these events can create up and down the supply chain, compounding the economic effect. In many situations, this new breed of the condition-based monitoring system may identify changes in the health of machines well before they fail, giving maintenance employees plenty of time to arrange an inspection or a planned outage to investigate and, if required, correct the problem. As a result, any corresponding disturbance to the whole production chain is reduced, resulting in considerable cost savings.
Remote monitoring available 24 hours a day, seven days a week
Another servicing regime that may be more suitable in a manufacturing sector is ‘condition-based maintenance,’ in which the ‘health’ or ‘condition’ of machines is continuously monitored 24 hours a day, seven days a week, and maintenance is only performed when the ‘health’ or ‘condition’ of a machine indicates that care is necessary because of measurable degradation in one or more machine condition indicators, such as increasing wear. Because of anticipated drawbacks like expense, complexity, and so on, some maintenance managers have been hesitant to embrace CBM. Traditional CBM technologies such as SCADA systems, which are sophisticated and somewhat expensive to acquire and install, and frequently require specialized personnel to evaluate the data produced, were undoubtedly true.
The advantages of condition monitoring are numerous, and they may have a significant influence on your productivity. As a result, you should think about employing a firm like ATTAR and getting the benefits.