#prescriptive maintenance

Reduced Risk and Lower Claims

Data-Driven Risk Assessment

Competitive advantage

• Demonstrated cost savings: Optimize maintenance, decrease downtime, and showcase Operational Excellence for potential competitive premiums. • Reduced environmental impact: Minimize energy consumption & plant emissions with Equipment Excellence to promote sustainability, valued by insurers for potential premium While effective implementation of Prescriptive Maintenance solutions creates a win-win situation for all stakeholders, Plant Heads & Senior Executives increasingly seek Fast ROI for any new Digital Initiatives amidst the challenging macro environment.

Hence, Prescriptive Maintenance solutions must drive adoption and showcase business impact within a financial year.

Predictive Maintenance Strategies in Chemical Plants

Addressing Counterfeit Drug Menace Through Predictive Maintenance with Digital Transformation:

Predictive maintenance can play a crucial role in preventing counterfeit drugs. Predictive maintenance involves using data and analytics to predict when equipment or systems are likely to fail, allowing for timely maintenance and preventing disruptions in the supply chain.

Improve Plant Safety

Predictive maintenance strengthens plant safety. In the chemical industry, critical asset failure can put employees in harm’s way. For example, if a pump transporting a chemical breaks, then that may result in a hazardous chemical spillage. Predictive maintenance is the most effective way to reduce asset failure, which can consequently reduce the risk of safety incidents.

By conducting necessary maintenance only, instances in which a maintenance engineer needs to visit assets operating in hazardous locations in the plant is also reduced. In a chemical plant, assets can often be placed in hazardous areas, and whenever an engineer needs to conduct maintenance in that area, there is a potential threat to safety. Predictive maintenance means maintenance personnel are only deployed when there is a problem to fix, and so unnecessary visits to hazardous locations can be avoided, and overall employee safety can be increased. To sum up, predictive maintenance helps chemical plant owners to reduce downtime of critical assets, improve plant operations (for example by improving efficiency and increasing plant uptime) and improve plant safety. All these factors are driving many chemical plant owners to seriously consider adopting predictive maintenance strategies.

Improve Plant Operational Efficiency

Predictive maintenance can also enable chemical plants to improve operational efficiency. There are several reasons for this. Firstly, and as mentioned above, predictive maintenance is a more effective way of reducing asset failure and the downtime that follows. Crucially for plant operations, unplanned downtime can result in missed output quotas. By predictively maintaining assets rather than preventively, unplanned downtime can be better avoided — giving plant owners a better chance of hitting output quotas. Real-time Vibration and other process parameter driven predictive maintenance can also help your chemical plant to reduce electricity consumption. It helps to determine the presence of a fault, whether a motor needs to be rightsized for its process, or whether the process is inefficient by design. By acting on this information, maintenance teams can reduce asset electricity consumption, therefore reducing plant energy consumption and ultimately reducing plant operating costs. Predictive maintenance also enables increases in overall equipment effectiveness (OEE), an important measure of operational efficiency. If assets are only replaced or serviced when an actual fault has been detected, then healthy assets can continue to run until it’s necessary to change them. Within a preventive maintenance strategy, healthy assets are often unnecessarily replaced, which decreases OEE and increases operations costs. Additionally, a predictive maintenance strategy also enables a more efficient use of maintenance resources. This is because maintenance personnel are only dispatched when an asset fault is detected, and not before. This lightens the maintenance workload, which subsequently reduces operating costs for the plant.

When a fault is detected, Real time IoT based predictive maintenance solutions can even make the act of maintenance more efficient, and consequently decreases the scheduled plant downtime window. By using real time data, solutions such as Vibit are able to determine the actual reason for the fault and offer recommended maintenance actions. This means that when the engineer inspects the motor, he or she knows exactly what to look for, and does not need to conduct a full asset inspection.

Unplanned downtime of critical equipment is bad news for any chemical plant owner. It can result in missed output quotas, higher maintenance costs and even threats to employee safety. The traditional method of reducing unplanned asset downtime is through preventive maintenance is not good enough, where maintenance is scheduled after a certain period of time, regardless of whether a fault has been detected. 

Reduce Unplanned Asset Downtime

Prescriptive maintenance is a new approach to maintenance that is rapidly gaining traction in the industrial sector. Unlike traditional preventive maintenance, which relies on fixed schedules and general assumptions, prescriptive maintenance uses data-driven insights to predict when equipment will fail, identify the root cause of the problem, and recommend the best course of action. By using this approach, companies can save time, reduce costs, and improve their bottom line.

In India, Trimasys is a leading IIoT solutions provider that specializes in prescriptive maintenance. With years of experience in the field, Trimasys has helped numerous companies across a wide range of industries implement this new approach to maintenance. In this blog, we will explore why prescriptive maintenance is the future of maintenance and how Trimasys can help your business save time and money.

Why Preventive Maintenance is No Longer Enough

Preventive maintenance has been the go-to maintenance strategy for decades. It involves scheduling maintenance activities based on the expected lifespan of the equipment, regardless of its current condition. While this approach can extend the life of equipment and reduce the risk of breakdowns, it is not without its drawbacks.

One of the biggest problems with preventive maintenance is that it is based on general assumptions and fixed schedules. This means that equipment may be serviced too frequently, leading to unnecessary downtime and increased maintenance costs. Alternatively, equipment may not be serviced often enough, resulting in unexpected breakdowns and costly repairs.

Another issue with preventive maintenance is that it is reactive rather than proactive. It relies on identifying problems after they have occurred rather than preventing them from happening in the first place. This can lead to extended downtime, lost production, and decreased efficiency.

The Benefits of Prescriptive Maintenance

Prescriptive maintenance, on the other hand, takes a proactive approach to maintenance. By analyzing data from sensors and other sources, prescriptive maintenance can predict when equipment is likely to fail and recommend the best course of action. This approach can help companies save time and money by reducing downtime, extending the lifespan of equipment, and improving overall efficiency.

One of the key benefits of prescriptive maintenance is that it is customized to each piece of equipment. Rather than relying on fixed schedules, prescriptive maintenance uses data to determine when maintenance is needed. This means that equipment is serviced only when necessary, reducing downtime and maintenance costs.

Another advantage of prescriptive maintenance is that it can identify the root cause of problems. By analyzing data from sensors and other sources, prescriptive maintenance can pinpoint the exact issue causing the problem. This allows maintenance teams to address the issue directly, reducing the risk of further breakdowns and costly repairs.

Prescriptive maintenance can also help companies improve efficiency by identifying areas where equipment can be optimized. By analyzing data on equipment performance, prescriptive maintenance can recommend adjustments to settings or procedures that can improve efficiency and reduce energy consumption.

How Trimasys Can Help

As a leading IIoT solutions provider in India, Trimasys has extensive experience in implementing prescriptive maintenance for companies across a wide range of industries. Their team of experts can work with your company to develop a customized prescriptive maintenance program that meets your unique needs.

Trimasys uses state-of-the-art technology to collect data from equipment sensors and other sources. This data is then analyzed using advanced algorithms to predict when maintenance is needed and identify the root cause of problems. The recommendations generated by the system are customized to each piece of equipment, ensuring that maintenance is performed only when necessary and in the most effective way possible.

Running a manufacturing unit is challenging due to various external and internal factors. While companies invest in the efficiency of their staff through corporate training, they also need to enhance the efficiency of machines. Therefore, the production becomes static at a certain saturation point. Nevertheless, production needs to be improved due to the wear and tear of the machines.