Calendar-based maintenance replaces healthy parts and can still miss the one that is actually failing. In a predictive programme we define measurement points, intervals and alarm limits for your critical assets and compare each reading with the last to catch degradation early.
The programme includes asset criticality analysis, a measurement route, alarm levels based on ISO 20816 / 10816, trending and a prioritised action list after every round. Our approach follows ISO 17359 condition monitoring principles.
Benefits
Less unplanned downtime
Failures are caught early and repairs move into planned stops.
Spare parts on time
Stock and lead times are planned on real need.
No secondary damage
A bearing defect is caught before it destroys the shaft, housing or winding.
Transparent maintenance budget
Health status and trends of every asset in one report.
Process
Criticality analysis
Prioritising assets by production impact, redundancy and failure history.
Route & points
Defining measurement points, directions, parameters and intervals.
Baseline
Recording each machine's reference signature.
Periodic rounds & trending
Monthly / quarterly rounds with trend and alarm tracking.
Action report
Prioritised findings, root causes and recommended actions.
Deliverables
- Asset criticality list
- Measurement route and point map
- Alert and danger limits
- Round health report (green / amber / red)
- Trend plots
- Prioritised action list
Applications
- Motor-pump sets
- Fans and blowers
- Gearboxes
- Compressors
- Conveyor drives
- Mills and crushers
- Cooling towers
- Air handling units
Frequently asked questions
How often should we measure?
It depends on criticality, speed and how fast faults develop. Monthly or bi-monthly intervals are common for general industrial equipment; critical assets may need more frequent readings or continuous monitoring.
Which faults can predictive maintenance detect early?
Most rotating equipment faults — unbalance, misalignment, mechanical looseness, bearing and gear defects, lubrication problems, resonance, electrically induced vibration and overheating — can be detected at an early stage.
Do we need an online monitoring system?
Not for every machine. In most plants periodic portable measurements give the best cost/benefit. Wireless or online sensors are worth considering for very critical, hard-to-reach or fast-degrading assets.