PdM Survey with Tom Wilk

Predictive maintenance is a continuous activity and it is really hard to drive PdM program success without having a clear set of goals and a vision that everyone understands. The industry trends for reliability and maintenance are changing fast and so are the organizations that want to keep up with the new technology. The results of PdM Survey from 2017 to 2018 show that the type of technology that a company uses effects its reliability program on a larger scale. In this survey, the participants were asked questions about the type of technology being used in their organizations and how satisfied they were with them.

In this episode, we covered:

  • Why you need goals and a vision in your PdM program!
  • The obstacles that get in the way!
  • What departments should be involved?
  • And much more!

The top technology options for PdM were oil analysis, vibration, and infrared. Then ultrasound came with an impressive use of about 60%. Electric motor testing was a frequently used tool too but respondents weren t in favor of using any predictive modeling software and neither did they have plans to use it in the future. All of these tools are quite mature and are widely used for proactive maintenance in the industry. The far reaching benefits of the proactive maintenance are being acknowledged by the organization with every passing day and they understand the operational and financial success it can deliver.

No matter how wide are the applications of a PdM program, there are always obstacles in its way. There are always lack of resources or budget constraints in the way but sometimes undefined benefits in terms of finance and operations can be a big challenge to get the support of management and executives. It also happens other times that the programs are poorly designed or executed and sometimes, lack of executive support becomes the biggest challenge to have a successful program out there. Most of the respondents in the survey agreed on the fact that their PdM program needed improvement and some just considered it satisfactory.

Others voted their programs to be either effective on not effective but almost all of them agreed on the performance improvement that a good PdM program can bring for their companies. When the respondent were asked whether a reactive or proactive approach was being deployed by their plants? The percentage of planned work or reactive maintenance was a slightly higher than predictive maintenance. Some of the responds preferred prescriptive maintenance where you make recommendation for diagnostics of a problem by using the collected data and running it against different variables.

When the respondents were asked about the kind of assets they were handling, most of them were using IOT based control system assets and others engaged with automation assets, electrical system assets etc. Then they were asked about the type of data collection methods they used and a huge percentage used paper system for data collection. After that, majority of them were using handheld data collectors and the use of sensors is also becoming trendy in the organizations. Overall statistics suggest that condition-based monitoring is becoming more reliable using mobile technologies and it is helping in improving maintenance strategies for organizations.

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