Predictive Maintenance Explained

▶ You can read the full post here

⌚Timestamps:
00:00 - Intro
00:33 - 1. Reactive maintenance
01:54 - 2. Preventive maintenance
02:37 - 3. Predictive maintenance
03:04 - Preventive maintenance vs. Predictive maintenance
03:39 - Utilizing Artificial Intelligence
05:19 - Applying predictive maintenance to the human body!
06:04 - Summary

=============================

Every device has a point of failure. What does that mean? Well, a new device fresh from the manufacturer is healthy and problem-free. Due to wear and tear on the device as it ages, its health slowly deteriorates and eventually it fails.

At this point, you need to perform maintenance for the device to get it back to a healthy condition. There are three main types of maintenance: Reactive, preventive, and predictive.

1) With reactive maintenance, you simply wait until a device breaks down and then perform maintenance on that device.

That means that you wait until the device fails and requires maintenance and then react, hence reactive maintenance.

For example, let’s say that you have a microwave oven at home. You use it for a few years until it gets to the point of failure and It won’t turn on anymore.

In this case, you repair the microwave or buy a new one. But it may take a couple of days for you to either repair the microwave or buy a new one.

That means, with this wait and react way of maintenance, you may not be able to use your microwave for a couple of days which is not a big deal.

However, if the same thing happens in a big industrial enterprise like an oil refinery, there might be huge consequences.

2) With preventive maintenance, you try to perform maintenance for the device long before the device gets to the point of failure.

For example, you can check the pressure transmitter regularly and before it gets to the point of failure to make sure that there won’t be any sudden interruption to the industrial process.

However, this is not very cost-effective. Because by performing the maintenance early, you waste device life that is still usable.

This is the time that we could still use the device without any maintenance but now we’re losing that because of early preventing maintenance.

3) With predictive maintenance, you predict when the device fails and schedule maintenance just before that.
Following this process, you minimize the device or machine downtime and maximize its lifetime.

How can we predict when a device fails? Well, this is simply done using the previous data that we have collected from a similar device in the past.

For instance, with the pressure transmitter example, there are already thousands if not millions of similar devices installed all over the world from the same brand. By analyzing the available data from these current devices, we can pretty accurately predict when a similar device fails.

The fancy term that we currently use or maybe overuse for utilizing this data is AI or Artificial Intelligence.

But, the basic principle comes down to analyzing historic and current data and making intelligent decisions for the future.

One of these intelligent or smart decisions that we can make is to predict when a similar new device will fail in the future and perform maintenance right before that, hence predictive maintenance!

What if we could apply this whole concept of predictive maintenance to human body organs? I mean what if we could replace a heart before it fails for example?

Could we then live forever? What if aging is a disease? Consider how the world would change if we could live forever?

The plan that Elon Musk and SpaceX have started for making humans multi-planetary seems in line with living a considerably longer life.

=============================

=============================

Missed our most recent videos? Watch them here:

=============================

To stay up to date with our last videos, make sure to subscribe to this YouTube channel:

=============================

=============================

#RealPars #maintenance #industry

[panosmallioris]

Predictive maintenance can also be divided into Condition based maintenance (CBM) where you predict the maintenance based of the health status from the data you collect from senors, and Remaining useful life (Rul) where you predict the remaining life of the machine at each point. Either way for PdM the most important thing is to collect lots of failure data in order to train your model predicting failure.

[houston-wkmd]

I wasn't ready for RealPars to start asking me about immortality, but I'm all here for it

[kasondensofwa]

Predictive maintenance is the future but I think we need a new profession in the engineering fraternity that will just be responsible for precise data collection.

[stoff_mnndao]

Simple and very instructive video. Predictive maintenance in plants will require huge amounts of data to be analyzed.

[dasistclutch]

Next time I forget to PM my equipment I’ll just show my boss this video and tell him I’m saving the company money.

[akiraHCF]

Eventhough it may be called preventive maintenance, many technicians or maintenance personnels do not change their spare parts based on the recommended intervals in vendors' manuals but according to fail history within their plant or based on info of similar operations as failures are based on various factors i.e running hours, operating and environmental conditions, liquid physical and chemical properties, assuming that there is no installation mistake or human error. Hence, it is safe to say that predictive maintenance have long been in practice. 😊

[strong]

How to get actual diagnostic parameter from transmitter?
we may consider to use HART/FF/PROFIBUS signal communication with Instrument Asset Management System (IAMS) and then integrate with PLC, PLC need to build up general rule & online detect specific parameter...

Normally temperature transmitter/pressure transmitter/DP type flow transmitter may follow maintenance engineer's experience to build up intelligent decision.

However other specific transmitter such as radar, coriolis flow, ultrasonic transmitter, valve positioner usually end user just call vendor to solve at plant. Vendor site engineer sometimes bring their specific software to know other specific trend / signal ...etc.
However those specific software also unable to integrate with IAMS...(whatever DTM already installed), Furthermore how is PLC can integrate with instrument for other diagnostic signal???

The video mentioned very good concept such as BN system 1 decision support but many type of instrument & different root cause related instrument life time...

For me, 100% agree video concept but I still don't image how to go in to detail & make it reliable..

[AlexandreSantos-ggil]

Great video, from Brazil thank very much.

[JKTCGMV]

As a hobby I happen to be working on an oil refinery video game and I intend to have equipment maintenance be a mechanic in the game. If anyone has ideas on how to gamify predictive maintenance, I’m open to suggestions :)

[kevinkshaji]

Taking the human physiology as an example, we can analyse the symptoms and can perform a predictive maintenance but what about a 4-20mA transmitter? I have not yet seen them throw any symptoms, they just simply stop. I would really like to know in detail about the predictive maintenance before I conclude it's just a buzzword

[nchimunyamuyuni]

I'm an electrical engineer from Zambia looking to get into electrical reliability, any suggestions on which sites offer cheap online certification?

[kocengineering]

Hello
Sir, Good explains tions
Yes sir we must be careful

[bernardjumbo]

IS REACTIVE MAINTENANCE SAME AS CORRECTIVE MAINTENANCE?

[СтепанМакухов]

Also during preventative maintenance it takes more total time for tool to be down. Just because it is preventative maintenance does not mean that the equipment does not have to go down, the difference is that during preventative maintenance you can choose least busiest time to do PM.

[jcerranom]

The point is most of the industrial equipment like that is running 24/7 and is not easy to schedule preventing maintenance and most cases the companies are not willing to do it, resulting in more down time when it breaks costing more thousands of dollars than a simply PM time could takes...

[eleccalengr]

Preventive is not necessarily replacing. Like change oil in cars, check breaks, etc

[PedroHernandez-bozw]

Sin duda el mantenimiento predictivo es lo mejor en cuanto a costos y confiabilidad

[ilyukchiljin]

sounds good as long as I don't have to collect the data myself or device manufacturers are willing to collect, analyse, and validate the data and make them available for its customers. Otherwise predictive maintenance is a severely limited solution that MAY or MAY NOT work even for the organisation that has the capacity to collect the data themselves.

[jesseainslie]

Not Forgetting prescriptive maintenance! All this (office) maintenance doesn't help much when non technical people are running it!

[NurbakytNurlanov]

Hello. How are you getting on with this AI idea since thie video was posted? Additionally, I wonder if you teach Machine Learning with these industrial components.