Predictive Maintenance Software

Physical assets such as machinery and equipment are at the core of manufacturing, power generation and many other industries. Without reliable and functional equipment, these industries simply would not exist. Maintaining the longevity and performance of everyday equipment is critical to ensuring that these industries continue to thrive and meet the demands of their consumers. 

Strategic maintenance management involves staying ahead of the curve before equipment fails. Unplanned downtime can result in both lost revenue and productivity, and taking a proactive versus reactive approach to maintenance is critical to minimizing unexpected outages. However, maintenance management is hard work and can require some advanced tools to do it right. Predictive maintenance software and other predictive maintenance tools can help enterprises across a variety of industries better predict equipment failure and anticipate when maintenance is necessary.

What is predictive maintenance software?

Predictive maintenance software combines powerful equipment monitoring tools and data analytics to analyze asset performance and predict potential equipment failures. Enterprises can then use this information to develop a proactive maintenance strategy to reduce unplanned downtime. Rather than waiting until a piece of equipment breaks to perform a repair, predictive maintenance software automates the maintenance process by scheduling maintenance at the first sign of a potential equipment issue. 

Predictive maintenance software works by using real-time monitoring tools to track equipment performance over time. Predictive maintenance tools such as sensors and gauges monitor any changes in equipment temperature, vibrations or sound to flag potential problems. This information then syncs with the software, which runs predictive maintenance analytics to assess equipment performance and determine if a repair is required or if an asset needs to be replaced altogether.

Predictive maintenance for diverse industries

Predictive maintenance software is a valuable tool for a variety of industries, including:

• Manufacturing - Predictive maintenance software is a cornerstone of smart manufacturing. Using IoT predictive maintenance tools, manufacturers can precisely monitor any changes in equipment conditions and detect early signs of potential failure. Predictive maintenance software can then schedule maintenance accordingly to prevent unplanned downtime and ensure maximum productivity.
  
  
• Transportation - Railway and other transportation industries benefit from predictive maintenance software by ensuring their assets stay up and running for as long as possible. Trains and other vehicles are a costly investment, and predictive maintenance tools can discover underlying issues that may evolve into bigger problems later. Using predictive maintenance software can help avoid unplanned downtime, reduce operating costs and prolong the lifespan of fleet vehicles.
  
  
• Utilities - Utility companies are tasked with providing services to thousands of customers, and equipment outages can result in drastic consequences. Predictive maintenance software integrates data analytics for utilities to track and analyze asset performance over time. The software can then schedule maintenance at the earliest sign of a possible equipment failure to prevent outages and increase overall business performance.
  
  
• Power generation - Predictive maintenance software can serve as a valuable tool for strategic power plant maintenance by monitoring and analyzing performance of critical assets over time. Using predictive maintenance tools such as equipment sensors, power plants can gain in-depth insight into asset conditions and perform maintenance as needed to avoid outages.

Predictive maintenance software helps companies take a proactive approach to maintenance to increase uptime, boost revenue and optimize asset performance. By capitalizing on the power of data analytics and predictive maintenance tools, enterprises can work smarter and more strategically to satisfy their customers and meet their revenue goals. 

FAQs

What is predictive maintenance software?
Predictive maintenance software is a type of maintenance software that monitors equipment conditions and performance over time to detect potential issues and schedule maintenance accordingly. Predictive maintenance software works by using predictive maintenance tools such as equipment sensors or gauges that monitor and measure variables such as vibrations, sounds and temperature. The software then runs predictive maintenance analytics to determine whether or not a repair is warranted. Using predictive maintenance software helps businesses take a proactive approach to maintenance by detecting early signs of equipment malfunction.

What is predictive maintenance?
Predictive maintenance, often abbreviated as “PdM,” is a maintenance philosophy that focuses on monitoring equipment performance during everyday operations to detect and prevent failures and outages. Instead of making a repair when a piece of equipment breaks down (as in “reactive maintenance”) or performing repairs regardless of equipment condition (as in “preventive maintenance”), predictive maintenance takes a strategic approach by revolving maintenance around real-time equipment performance data. Predictive maintenance involves using predictive maintenance tools such as temperature gauges, vibration monitors and others to monitor equipment condition over time. This information then syncs with predictive maintenance software to analyze performance trends and determine if maintenance is warranted. Predictive maintenance can help industrial enterprises increase uptime, prolong the lifespan of their assets, boost productivity and increase revenue.

What are the types of predictive maintenance?
There are several main types of predictive maintenance, including:

• Vibrational analysis - This method of predictive maintenance uses sensors to monitor equipment vibrations and identify any changes that may indicate an issue. Vibrational analysis can help detect looseness, misalignment or wear and tear of equipment.
  
  
• Infrared analysis - This type of predictive maintenance monitors the temperature of equipment to identify potential issues that may require further action. A change in equipment temperature is often one of the first signs that there is some sort of problem, and using thermal imaging tools can help enterprises better monitor operating conditions of their assets.
  
  
• Acoustical analysis - This predictive maintenance method monitors changes in the sound of equipment or assets. Changes in sounds emitted by equipment may indicate the need for a repair, and predictive maintenance tools such as ultrasonic sensors can detect subtle changes in sound that are inaudible to employees.

These predictive maintenance tools can work individually and in conjunction with one another to accurately assess machinery condition. Enterprises can then analyze this information to determine if an asset requires maintenance or replacement.