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How much do you spend on downtime?

Downtime Intelligent Service (b)

Reviewing your vacuum and abatement maintenance regime may help you understand the true impact on your manufacturing costs. Reactive, preventative and predictive maintenance regimes represent different approaches to maintaining and repairing equipment. Each has its own set of advantages and disadvantages. 

Let's compare these maintenance regimes based on their key characteristics:

1. Reactive Maintenance: unsecured production.

Also known as run-to-failure or breakdown maintenance, reactive maintenance involves waiting for equipment to fail before performing maintenance or repairs.

  • Advantages: Low initial costs, as no investment in monitoring equipment or scheduled maintenance planning is required. It can be suitable for non-critical equipment where downtime has minimal consequences.
  • Disadvantages: Unexpected equipment failures can lead to increased operating expenses, extensive damage, higher repair costs, longer downtime, decreased productivity, and increased safety risks.

2. Preventative Maintenance: costly over servicing?

Also known as scheduled or planned maintenance, preventative maintenance involves performing regular maintenance tasks according to a predetermined schedule, regardless of equipment condition.

  • Advantages: Reduces the likelihood of unexpected equipment failure, prolongs the equipment's lifespan, and can be planned around production schedules to minimize downtime.
  • Disadvantages: Maintenance tasks may be performed more frequently than necessary, leading to increased operating expenses and potential over-maintenance. Additionally, it may not prevent all unexpected failures.

3. Predictive Maintenance: intelligence service regime.

Predictive maintenance uses real-time data, advanced analytics, and condition monitoring techniques (such as vibration analysis, thermal imaging, or oil analysis) to determine the equipment's actual condition and predict when maintenance is required.

  • Advantages: Minimizes downtime by performing maintenance only when needed, reduces the number of unnecessary maintenance tasks, optimizes resource allocation, and can lead to significant cost savings.
  • Disadvantages: Requires investment in monitoring equipment, software, and skilled personnel. The accuracy of predictions depends on the quality of data and analysis.

In summary, preventative maintenance is a more structured approach that relies on a predetermined maintenance schedule, while predictive maintenance uses real-time data and condition monitoring to optimize maintenance tasks. Reactive maintenance is a less proactive approach, waiting for equipment failure before taking action. This approach could be very detrimental if the average cost of downtime is high. 

When comparing these regimes, predictive maintenance often offers the best balance between cost savings, efficiency improvements, and equipment reliability. However, the choice of maintenance regime should be tailored to an organization's specific needs, resources, and risk tolerance. 

Cover image of document titled "Cost Comparison of Maintenance Regimes"

To read more on this subject, download Erik Collart’s article ‘Cost Comparison of Maintenance Regimes’, below.

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