Before the introduction of the Predictive maintenance techniques, industries were depending upon the traditional preventive measures. To take care of the asset’s health and longer durability, all assets were required to undergo a physical inspection every quarter.
This is a daunting task as it involves a pool of resources time, effort to look into any possible defect. Also, handling the emergency situation is not streamlined which often results in a major catastrophe like unplanned downtimes and results in huge loss.
This is where a new Predictive system needs to be implemented for zero downtime and to increase operational efficiency.
Breakdown of cost in an Automobile industry
Take, for example, the automobile industry. When you walk into a car dealer showroom, the net price of a car will be overwhelming to digest. But, each comes with a special price as per the special features & advanced technologies used in the car.
Before delving into the predictive maintenance advantages, first, let us understand the cost & importance involved in each of these car assets. This is will justify why we need robust technology (Pdm) to support these invaluable assets.
- Raw materials and the auto parts cost accounts for 57% of the total price.
- Design & Engineering the vehicle blueprint model, along with research and development leads to 16 % of the cost.
- Average advertising costs for each unit sums around 2000 dollars.
- Dealership cost accounts to 1500 dollars and finally
- Sales tax is around 5000 dollars.
Benefits of Predictive Maintenance
Now, let’s look briefly in this section why every industry is more inclined towards predictive maintenance and what’s the buzz all about. One of the salient features of predictive analytics in automobile industry is affordability. This shows how it is reducing the manufacturing costs to a significant amount.
1. Cut Down on Equipment Costs
With high-end auto parts which in many cases imported from giant manufacturers worldwide, the corresponding maintenance costs is always a hidden cost factor.
Hence, diligent care should be taken to maintain the auto parts and other machinery that has a huge investment. Unlike the traditional preventive measures when if one part is damaged the entire part will be replaced causing huge monetary loss.
But, with Predictive maintenance software and techniques, it will cut down the equipment replacement cost.
2. Decrease labor costs
By implementing Predictive maintenance, cutting down the equipment costs also indirectly helps to cut down the labor costs. It will alert the employee of potential damage in the near future, thereby reducing the labor costs as well as the repair expenses.
In a study, it is revealed that 40% of the maintenance costs can be reduced by incorporating the Predictive Maintenance in any manufacturing industry.
3. Reduce Maintenance Costs
While purchasing a new unit for the automobile industry, one cannot just ignore the routine maintenance checkups. We cannot just install it then forget all about it.
As long as the machine is up and running, people will be turned into a mindset to check only when something goes wrong terribly. The predictive analysis provides the capability to perform routine checkups to detect the problem early and avoid any production downtime.
4. Improve safety & Reliability
Vehicle collision is the number one cause for road accidents which may be fatal. This is true especially in expressway where vehicle high speeding is inevitable. Hence, safety is the number one priority while designing a car product for any automobile industry.
Similarly, reliability is the key component when it comes to maintaining assets in the automobile industry.
5. Extend the Life of Equipment
According to a study conducted by the Plant Engineering survey, half of the monetary loss occurs due to the prolonged usage of the machine. Aging machine and the negligence to service them in due time leads to huge loss forcing them to change the entire machinery part.
With proper predictive maintenance system in place, the expectancy of each asset can be extended to a significant amount. Through routine check-ups, analytical tools can be made possible.
6. Increases the productivity of the Resource Time
Highly skilled technicians are always on demand for handling expensive machinery parts. Hence, using their valuable time without wasting on mundane tasks is important.
Predictive maintenance will greatly reduce the wrench time. It precision tells the experts what part needs to be checked and needs to be replaced without affecting the overall functioning of the unit.
Thus, research proves that even a one minute of downtime in the automobile industry leads to a whopping loss of around 22,000 dollars which can be greatly reduced by predictive maintenance measures. This predictive analysis detects certain patterns and behaviors for each asset to alert within the internal departments.
Save company asset and money to increase the efficiency of the overall production unit with these cost-benefit analysis.
Sarah Johnson is a content marketing specialist who loves to share new emerging techniques.