5 types of Maintenance that will Improve Manufacturing Productivity

Regardless of the size of your business, itā€™s clear that thereā€™s a solid correlation between plant profitability and your facilityā€™s productivity. Maximizing Productivity is the main goal of any industrial company, whatever the nature of its business and the type of good. For the constant improvement in productivity and process to be successful, it is important to embrace management and the workforce involving all employees from operators to facilitators and supervisors.

According to the report, the global predictive maintenance market size is predicted to grow from USD 4.0 billion in 2020 to USD 12.3 billion by 2025.

Few consequences of machine failure can contain a failure in the quality of your product as well as the potential effect on your businessā€™s environmental, health and safety performance parameters. The end output is also not up to the mark because of an unplanned obstruction and cannot be retrieved without cost implications. Hence, many types of maintenance exist in order to offer manufacturers opportunities to improve their production lines.

Letā€™s discover various types of maintenance in manufacturing.

Corrective Maintenance

Corrective maintenance is performed exactly after a fault has been detected on a piece of equipment or a production line: its intent is to make the piece of equipment operate normally again so that it can execute its assigned function. Corrective maintenance can either be planned or unplanned based on whether or not a maintenance plan has been generated. If the failure that disorganizes the production process has not been predicted by other types of maintenance, likewise preventive maintenance, industrial maintenance technicians tackle the concerns as soon as it occurs. This type of involution can be expensive for companies.

To restrict the repair cost, manufacturers choose corrective maintenance, which includes repairing and resolving the problem at a lower cost and more quickly. Corrective maintenance provides technicians the possibility to execute their interventions without delay, even it depends on them whether they want to keep the piece of equipment on the mark, right when an issue has been detected or later. Unplanned corrective maintenance can rapidly become more expensive than planned one because it can tend to costs that couldnā€™t have been predicted.

Preventive Maintenance

This type of maintenance is carried out by technicians teams and managers before any malfunction or failure occurs. Its goal is to minimize the probability of the breakdown of a piece of equipment, component, or spare part. In order to apply such maintenance, teams have to consider the partā€™s history and maintain track of the former failures. They are hence capable to recognize the time ranges during which a piece of equipment might break down.

This type of maintenance is reported as planned because it depends on well-established maintenance programs and hard facts. Preventive maintenance utilizes the concept of ā€œMean Time Between Failureā€ (MTBF) to discover the best interval at which to replace parts based on when they have failed in the past. It operates best for parts that run across regular use and predictable wear-and-tear. The digitalization of industrial organizationsĀ has offered manyĀ computerizedĀ and technological solutions that enable technicians to perform, analyze,Ā keep trackĀ and plan preventive maintenance efficiently.

Predictive Maintenance

The evolution of data processing, machine learning and analysis solutions has enabled manufacturers to outline predictive maintenance based on the projection of failures and malfunctions. This type of industrial maintenance enables companies to predict concerns by planning the required involutions and maintenance operationsĀ based on predictions. It thus makes it feasible to restrict the expenses caused by unexpected breakdowns,Ā equipment downtime as well as production disruption.

The aim of predictive maintenance is to strike the risky zone of maintenance not too frequently and not too rarely. This avoids risks in over-maintenance likewise excessive parts and labor costs, waste and improved risk of human error. It also prevents concerns related to under-maintenance likewise critical failure, unplanned downtime and destruction to machinery or employees.

In order to do this, data is gathered from factory machines enclosed with IoT sensors which are then monitored based on both current and historical data, often using machine learning, to find trends and estimate failure.

Systematic Preventive Maintenance

This type of preventive maintenance is differentiated by its frequency. It is periodic and orderly carried out by the technicians at distinct time intervals before. This enables components and spare parts to be restored regularly, increasing machine productivity. Systematic preventive maintenance hence depends on regular inspection of several types of equipment, allowing maintenance technicians to gather the necessary data on the several components of the production line and to efficiently prevent breakdowns and repair costs.

Conditional Preventive Maintenance

Among all types of maintenance mentioned above, condition-based maintenance is the most complex to implement. Its goal is to prevent failures and needs regular check-ups of the state, the efficiency and other indicators of the system. Ā Conditional preventive maintenance contains analyzing the key parameters and indicators of the propertyā€™s operation and applying the required corrective actions to predict any failure or malfunction. Many developing computer tools are available to automate such type of industrial maintenance. Hence, technicians, as well as maintenance workers,Ā canĀ clarifyĀ and ease their work by selecting the digitalization of industrial maintenance processes.

Adopting the correct tool and applying a type of maintenance that is suitable for a companyā€™s requirements enables it to differentiate itself from its competitors and to take advantage of significant competitive benefit.