Your industrial equipment is the heart of your company’s day-to-day operations. If it goes down, a lot of your infrastructure and output goes with it.
That’s why real-time equipment monitoring and preventive maintenance are so important. They help you avoid unexpected downtime, which would otherwise limit production and lead to missed deadlines. They also reduce repair costs and keep your equipment safe for everyone who uses it.
In the long run, these practices do more than save money and time. They give your company a competitive advantage through heightened operational efficiency and reliability. Learn how to monitor the health of your industrial equipment and extend its lifespan through preventive maintenance and parts washing.
To monitor your industrial equipment, you need technology that can collect data in real time or find incredibly small flaws. This lets you and your maintenance teams address problems proactively instead of just reacting to them.
Some companies are content with just one of the monitoring methods below, but combining all three can lead to a more complete and reliable understanding of your machines’ health.
This process uses Internet of Things (IoT) technology to track your machines’ operational data. For instance, it might track things like:
The machine monitoring system can use this data and the other information collected by its sensors to flag potential issues. For example, if a compressor starts using more electricity to generate the same air pressure, some part of it is likely experiencing inefficiency or wear.
This approach is perfect for identifying gradual degradation in industrial machines. You can then address the problem by repairing or replacing the strained or damaged parts. The data can even help you optimize energy consumption and machine processes to make those parts last longer.
This monitoring method is typically only used when an industrial machine is shut down. It requires hands-on work from trained technicians, and its specificity makes NDT ideal for spotting cracks, voids and other small flaws that can lead to big problems. Some of the most common NDT techniques include:
These techniques allow the specialists to spot surface-level cracks in metal components and detect internal defects in welds and other critical components. They can then inform you which parts are damaged and how to address the specific problems facing those parts.
When it comes to equipment monitoring, CBM is king. It uses specialized IoT sensors to gather data in real time, similar to machine monitoring. The difference is that these sensors are geared toward detecting sudden problems. They’re keyed in to things like:
All this data allows them to rapidly identify and diagnose emerging problems. For example, should one internal mechanism begin to grind slightly against another, the CBM can identify the sound’s origin. It can then warn you about the parts in question so you can adjust or repair them before they cause irreversible damage.
This ability to identify and flag sudden problems makes CBM an excellent baseline, as far as equipment monitoring is concerned. Then, you can stack machine monitoring and NDT on top of it to shore up its weaknesses.
Industrial equipment monitoring systems are only part of the preventive maintenance process. If you really want to improve the health of your equipment, you’ll need a robust maintenance strategy.
Think of the maintenance practices below as the arms to your monitoring system’s brain. They can respond to any problems the system identifies, yes, but they can also prevent issues in the first place if used correctly.
All industrial machines need a consistent maintenance schedule.
Each one should come with a manual from the original equipment manufacturer (OEM). The manual details common maintenance practices, such as oil and filter changes, that you will need to perform periodically. Note these practices and ensure they are carried out on time.
You will likely need to adapt these guidelines to your environment and the machine’s activity, though. Dirtier, harsher settings may mean you need to clean the equipment more frequently. The same is true if a piece of equipment is placed under high levels of stress often.
You can track these altered rates with a computerized maintenance management system (CMMS). It will also make sticking to the maintenance schedule easier in general.
Document everything you can about your maintenance practices, including:
These records will eventually allow you to identify recurring problems and help you optimize your maintenance intervals over time. Once you observe these patterns and develop the ideal maintenance intervals, your machines may experience fewer breakdowns and an extended lifespan.
Maintenance records are also important for processing warranty claims, so be as detailed as possible.
Visual inspections aren’t as effective if your equipment is dirty, but the problems dirt and grime cause don’t stop there. They can also trap heat inside your equipment, forcing motors and bearings to run hotter than normal. Oil, dust and other residues can also be a fire hazard. This is especially true for machines that are forced to operate at higher temperatures due to grime. These contaminants can also interfere with the function of hydraulics and other sensitive systems.
This is why regular cleaning is so important. It makes industrial machines easier to inspect visually while helping them run safer and better.
Your equipment’s lifespan is directly tied to its cleanliness, especially if you’re rebuilding or overhauling industrial equipment. This is where the parts washing process comes in.
Parts washing equipment cleans dirt, oil and grime from specific equipment components. It is often automated, but some parts washing machines require people to manage cleaning. Either way, it is one of the most thorough and effective component cleaning processes available. It is one of the best ways to prevent industrial equipment corrosion. It also:
All these benefits can radically extend the lifespan of industrial equipment, especially if the process is optimized.
New England Sales offers a wide selection of industrial parts washing equipment and so much more. Whether you’re a project engineer, a CEO or something in between, we are here to listen to your needs and recommend the best equipment for you. We partner with some of the best manufacturers in the business to bring high-quality equipment to you in the Northeast.
To learn more about parts washing equipment, fill out our contact form or reach out at 781-826-8855.
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