Meeting production goals demands great synchronization between operations and maintenance teams. Yet, it’s not uncommon for plant managers to change maintenance strategies on the run. Often switching calendar-based programs for a run-to-failure approach.

This strategy may work for some. But, it isn’t the most fitting or convenient for some facilities.

Here’s where Predictive Maintenance (PdM) comes into action. As a genuine tool that can bridge the gap between operations and maintenance.

Wishing to share my experience on the subject, here are the three ways I’ve seen predictive maintenance raise plant operations.

1. Tighter asset monitoring leads to better responses

Unlike preventive and corrective programs, PdM integrates digital tools that detect operational anomalies. It’s fair to say the main goal is to empower teams to engage in proactive and cost-effective asset maintenance.

First off, IoT sensors compile real-time data from vital assets of the plant. The reads build historical datasets and behavioral patterns reflective of the asset’s health.

Keeping the data clean is crucial! And demands innate process expertise and field know-how. Only experts fit the role to discriminate the bad reads and faulty measures from the good ones.

Moreover, a PdM asset management software applies these clean data records to project downtime. Artificial Intelligence (AI) and Machine Learning (ML) algorithms run case scenarios. A call for action comes to life as per asset criticality.

Plant operators and maintainers gain predictive analytics perspective that helps gear up strategies to:

  • Prompt faster and assertive responses.
  • Avoid breakdown and shutdown.
  • Increase uptime and reliability.
  • Streamline resources (time and costs).
2. Cleaner work order prep and execution

Assembling a crew to fix upsets is something every maintenance team deals with day in and day out. Their goal is always the same: helping fellow operators from crashing production figures!

Yet, when maintenance strategies lean towards a reactive approach, tackling any issue can get more challenging.

Case and point: creation, approval, and closure of work orders. Common mistakes, such as incorrect service details or lack of asset data, add uncertainty and compromise reliability.

Luckily, PdM is changing the landscape in work order management for good by:

  • Integrating user-friendly interfaces that automate the workflow according to the facility.
  • Adding transparency at every step of the road.
  • Enhancing job tracking, accessibility, scheduling, reporting, and closing.
3. Informed decision making

As we’ve seen so far, PdM empowers plant managers, operators, and maintainers to make informed decisions on their assets.

The combination of trustworthy/accurate data with AI and ML tech tailored to the plant’s realities serves a great purpose at helping:

  • Identify critical assets in danger of breakdown early on.
  • Analyze derived technical and financial scenarios.
  • Align teams to work better together.
  • Schedule maintenance tasks smartly and promptly.
  • Save resources (time and money).

For those reasons alone, don’t miss the chance to strengthen PdM practices in your plant. They will be beneficial for all.

If you want more information or need consulting, please feel free to send me a message.


𝑷𝒉𝒐𝒏𝒆: 248-622-2850