The Maintenance Evolution
Reactive Maintenance
Fix it when it breaks
Cost LevelHighest
DowntimeMaximum
Problems
- ✕ Unplanned downtime
- ✕ Emergency repairs
- ✕ Collateral damage
- ✕ Safety risks
Preventive Maintenance
Fix it on a schedule
Cost LevelMedium-High
DowntimeScheduled
Problems
- ✕ Over-maintenance
- ✕ Wasted parts
- ✕ Unnecessary labor
- ✕ Still unexpected failures
Predictive Maintenance
Fix it when needed
Cost LevelLowest
DowntimeMinimal
Benefits
- Fix only when needed
- Plan maintenance windows
- Prevent catastrophic failures
- Extend equipment life
Proven Savings
40-60%
Maintenance Cost Reduction
Average savings from switching to predictive maintenance
70-90%
Unplanned Downtime Reduction
Prevent failures before they cause production stops
20-40%
Equipment Life Extension
Address issues early before they cause permanent damage
25-50%
Spare Parts Inventory Reduction
Order parts when needed, not 'just in case'
Sensors for Predictive Maintenance
Vibration Sensors
What It Monitors
Bearing wear
Imbalance
Misalignment
Looseness
Best For
Motors, Pumps, Compressors, Fans, Gearboxes
Temperature Sensors
What It Monitors
Overheating
Friction
Electrical issues
Process deviations
Best For
Electrical panels, Bearings, Motors, Transformers
Current Monitors
What It Monitors
Load changes
Phase imbalance
Insulation degradation
Efficiency loss
Best For
Electric motors, Pumps, HVAC systems, Compressors
Acoustic Sensors
What It Monitors
Leaks
Valve issues
Pump cavitation
Bearing defects
Best For
Compressed air, Steam traps, Hydraulic systems, Pipelines