COE-PM is aiming to establish itself as a center of excellence in Predictive Maintenance research and development both domestically and internationally and attract both local and international research grants. With the support of BUE community and our research collaborators in Egypt and abroad, I am confident that COE-PM will continue to grow and always be a part of new research innovations which at the end serve the national interest and all humanity.

WHAT IS PREDICTIVE MAINTENANCE?

Predictive maintenance (PM) techniques are used to determine the condition of in-service equipment in order to predict when maintenance should be performed. PM tools evaluate the condition of equipment by performing periodic or continuous (online) equipment condition monitoring using application-based sensors and signal processing techniques. The ultimate goal of PM is to perform maintenance at a scheduled point in time when the maintenance activity is most cost-effective and before the equipment loses performance within a threshold. Since maintenance actions are performed based on the actual need of the system, This approach ultimately leads to cost savings over routine or time-based preventive maintenance where a piece of equipment gets maintained whether it needs it or not. Moreover, adopting Predicted Maintenance strategies allow convenient scheduling of maintenance actions, and prevent unexpected equipment failures. By knowing which equipment needs maintenance and what type of component failure, maintenance work can be better planned (spare parts, man-hours, etc.). Other potential advantages include increased equipment lifetime, increased plant safety, fewer accidents with negative impact on environment, and optimized spare parts handling.

The "predictive" component of predictive maintenance stems from the goal of predicting the future trend of the equipment's condition. This approach uses principles of statistical process control to determine at what point in the future maintenance activities will be appropriate. Most PM inspections are performed while equipment is in service, thereby minimizing disruption of normal system operations. Adoption of PM can result in substantial cost savings and higher system reliability.
PM can be applied to many areas including, but not limited to, Aviation, transportation, energy, and civil structures. Any field with complex mechanical systems and high availability requirements is a good candidate for the application of PM.

WHY PREDICTIVE MAINTENANCE IS REQUIRED?

Maintenance costs are a major part of the total operating costs of all manufacturing or production plants. In the United States, average maintenance cost for food-related industries represent about 15% of the cost of goods produced. For iron and steel, pulp and paper, and other heavy industries, it represents up to 60% of the total production costs. Surveys have shown that 33% of maintenance cost is wasted as the result of unnecessary or improperly carried out maintenance. The U.S. industry spends more than $265 billion each year on maintenance of plant equipment and facilities. This equates to a loss of more than $80 billion a year due to ineffective maintenance management practices. Cleary this is an area that needs a lot of attention and action.

AREAS OF APPLICATION

Areas of application for PM technologies include but not limited to:

  • Aviation
  • Energy
  • Civil Structure
  • Transportation

Abdel-Moez Bayoumi, Ph.D, P.E