Conceptual definitions in IATF 16949
①Preventive maintenance (PM)
Regular activities (time-based periodic inspections and maintenance) planned to eliminate the causes of equipment failure and unplanned production interruptions are an output of manufacturing process design.
Original English text: planned activities at regular intervals (time-based, periodicinspection, and overhaul) to eliminate causes of equipment failures and unscheduled interruptions to production, as well as output of the manufacturing process design.
2. Predictive maintenance (PdM)
A method or set of techniques for evaluating the condition of in-service equipment by periodically or continuously monitoring its condition in order to predict the specific time when maintenance should be performed.
Original English text: anapproachandsetoftechniquestoevaluatetheconditionofin-serviceequipmentbyperformingperiodicorcontinuousmonitoringofequipmentconditions,inordertopredictwhenmaintenanceshouldbeperformed.
2. How to understand this?
Preventive maintenance and predictive maintenance are important maintenance methods to consider when implementing Total Productive Maintenance (TPM).
Preventive maintenance is the most common, while predictive maintenance is not applicable in every situation.
IATF 16949 Clause 8.5.1.5 Total Production Maintenance sets specific requirements for equipment maintenance objectives. For predictive maintenance, it is no longer mandatory, but rather "as applicable".
Preventive maintenance refers to planned and regular equipment maintenance and parts replacement, which usually includes several types such as maintenance, regular usage inspection, regular functional testing, regular disassembly and repair, and timed replacement.
Periodic maintenance, including periodic cover haul, should be considered a preventative maintenance procedure.
Examples of preventative maintenance:
First service (oil change) after 3000 kilometers for a new car
Clean production equipment regularly and replace damaged parts.
Predictive maintenance involves using various methods to collect data and signals (which can be intermittent or continuous), analyze and judge the deterioration trend of equipment, the location of failures, the causes, predict changes and developments, and propose preventive measures to prevent and control possible failures.
Predictive maintenance is essentially similar to SPC.
Example of predictive maintenance:
Using detection equipment such as infrared thermal imagers, vibration analyzers, and ultrasonic instruments, the operating parameters of the equipment, such as temperature and vibration, are detected and compared with the standard operating parameters of the equipment to determine whether maintenance is needed and how to arrange maintenance work in a targeted manner.
3. Advantages and future trends of predictive maintenance
The biggest advantage of predictive maintenance is the reduction in overall cost. A study by the Federal Energy Management Program (FEMP) in the United States estimates that a properly functioning predictive maintenance program can provide 30% to 40% savings compared to preventative maintenance. According to relevant statistics, on average, implementing an industrial predictive maintenance program can result in the following savings:
Return on investment: 10 times
Maintenance costs reduced by 25% to 30%.
Fault elimination: 70% to 75%
Downtime reduced by 35% to 45%.
Production increased by 20% to 25%.
With the development of the Internet of Things (IoT), the application of big data, and the intensified competition brought about by smart manufacturing, predictive maintenance will see explosive growth in the coming years. So, are you ready?
