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Lots of organizations use different types of maintenance. Maintenance is not only done when an asset is broken, it is also done to increase asset performance. It is also done to avoid breakdown. One of the maintenance types is condition-based maintenance.
Condition-based maintenance can be beneficial to your organization when you know what is the benefit of it?
It has a vast market! According to the markets and markets, “The global machine condition monitoring market size is projected to grow from USD 2.6 billion in 2021 to USD 3.6 billion by 2026; it is expected to grow at a CAGR (Compound Annual Growth Rate) of 7.1% from 2021 to 2026.”
What Is Condition-Based Maintenance?
Condition-based maintenance as the name suggests maintenance is done based on the current condition of the asset. In this process assets are inspected thoroughly, past data is utilized of each asset.
Maintenance is not only done for avoiding breakdown it is also done in order to enhance the performance of assets so that productivity increases.
Monitoring and tracking are an important part of condition-based maintenance. When you keep monitoring assets you can schedule maintenance as per the requirement.
With the regular inspection of an asset, you can use it to its optimum level and schedule maintenance when it is about to break.
What Are the Benefits of Condition-Based Maintenance?
1. Reduced Equipment Failure
When equipment is provided maintenance regularly their failure chances are reduced and makes the equipment more reliable.
We know when equipment fails it reduces the productivity of the organization as the production process halts. Maintained equipment not only performs better but also increases safety for employees.
2. Maximizing Asset Life
Providing maintenance on time minimizes sudden asset failure chances and enhances asset life. It positively impacts the bottom line because maintenance expenses are minimized, and asset productive life is increased.
For instance, if the asset is used 10 percent more than expected life that means you have achieved profit from the asset.
3. Decreased Maintenance Expenses
When you emphasize proactive maintenance it schedules maintenance in advance, and you will notice as time goes by your maintenance expenses will keep on decreasing.
The main reason behind it is that when maintenance is not scheduled then there are so many activities that need to be performed but when maintenance is scheduled activities keep on decreasing.
It also decreases the stress of the maintenance team.
4. Quick Maintenance
In condition-based maintenance inspection is long, but maintenance work is done in a short time because you already know in advance what the issues are! The maintenance is scheduled, and issues are resolved and save time.
Since inspection enables to predict failure & resolve the problem before it occurs. It also plays a crucial role in decreasing downtime and increasing uptime.
What Are the Disadvantages of Condition-Based Maintenance?
Condition-based maintenance is cost-effective in the long run, but when you implement condition-based maintenance then you will need some tools such as sensors that measure the vibration of an asset and work as a maintenance indicator of the asset.
You also need to ensure that you choose the right kind of sensor tool.
Condition-based maintenance needs regular inspection of assets in order to avoid equipment failure. It means you always need a maintenance team on standby in order to keep assets competitive.
Furthermore, the maintenance team shall be knowledgeable, skilled, and must be able to handle pressure.
What Are the Reasons to Implement Condition-Based Maintenance in Your Business?
1. Cost-Effective in the Long Run
As businesses need to invest money in order to grow business. Similarly, organizations need to invest in software and monitoring tools in order to save maintenance expenses.
Maintenance costs can eat up an organization's profit but in the long run, you notice minimized maintenance bills, and the organization's profit will increase.
2. Reduces Maintenance Work
Maintenance work will be reduced because assets are either maintained or need very specific work. Maintenance work mainly includes things such as changing the air filter, engine oil, lubrication, changing parts if required, etc.
Once everything is settled, the maintenance team only needs to do activities that are usually not time-consuming.
3. Increased Equipment Performance
Failure only occurs when assets are kept in use and maintenance is not provided. Condition-based maintenance uses the asset, but maintenance is also given. It means equipment failure is reduced and performance is optimized.
4. Better Utilization of Resources
Because inspection and monitoring are major parts of the maintenance. Therefore, it keeps track of equipment part performance which means they are only changed when they need to be changed. So, assets are used till they are productive, and their condition is useful.
Conclusion
In a condition-based maintenance strategy you need to keep proper track of maintenance otherwise it will not be effective. The benefits of condition-based maintenance can be seen quickly.
It also minimizes maintenance expenses and increases asset life; however, you need to perform inspections regularly. You can also use CMMS software that specializes in maintenance scheduling.
CMMS can save you from lots of problems and it can be very productive in terms of keeping equipment in the best condition.
Frequently Asked Questions (FAQs)
What are the four types of asset maintenance?
Four types of maintenance are given below:
1. Preventive Maintenance - Preventive maintenance is scheduled maintenance that is done in advance so that equipment failure does not occur. Preventive maintenance is scheduled depending upon the usage or time duration. For example, maintenance is performed after 2-3 months (time) or after 2000-km (usage)
2. Predictive Maintenance - Predictive maintenance also schedules maintenance in advance. However, inspection is done regularly so that equipment is used to its full extent. Predictive maintenance is one of the most used maintenance types in organizations.
3. Condition-based Maintenance - Condition-based maintenance also inspects equipment so that breakdown can be avoided. It enables you to utilize assets to their full capacity. However, you need a maintenance team to ensure that all parts of the equipment are working fine.
4. Emergency Maintenance - Emergency maintenance is that maintenance in which equipment breakdown has occurred and now it needs to be brought back into working condition.
What are the tools & technologies built for condition-based monitoring?
Condition-based monitoring technologies are discussed below:
1. Vibration Analysis - Vibration is used to check the performance of equipment. Vibration too analyzer searches for patter and signal & key performance indicators are also checked.
2. Ultrasound Technology - This is used to see if there are gas leakage in exchangers, condensers. Ultrasound also lets you know the quality of the lubricant.
3. Oil Analysis - With this tool oil is analyzed and checked the quality of the oil. For instance, engine oil viscosity is measured, and oil is examined if there are contaminants in the oil.
3. What is the objective of condition-based maintenance?
The objective of condition-based maintenance is to identify a potential problem in a piece of equipment. Condition-based maintenance calculates when an asset will work fine after inspection of the asset. When equipment is about to fail, proactive maintenance is provided. It minimizes the time spent on maintenance work & improves safety for workers.
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