Maintaining industrial machinery is both costly and time-consuming, leading to considerable downtime. To ensure competitiveness and a strong ROI, it is essential to adopt new technologies and management strategies that reduce maintenance needs.

By 2026, the global market for maintenance, repair, and operations is expected to reach $701.3 billion, largely due to the costs associated with aging assets. Mechanical failures, operator errors, insufficient maintenance schedules, and poor design are frequent causes of unplanned downtime.

One method to reduce maintenance requirements is to install components that need little to no upkeep, such as ultrasonic clamp-on meters. These meters, used in industries like water distribution, are designed to be nearly maintenance-free because they lack moving parts that could wear out.

Another way to increase ROI is by implementing a preventive maintenance (PM) program. In 2020, 76% of global manufacturing companies focused on PM, which involves scheduled checks to detect issues before they cause disruptions. While PM can extend the life of equipment and enhance resale value, it also adds to the overall cost of ownership and varies by the type of machinery.

Predictive maintenance (PdM) is a more advanced approach that uses analytics and AI to foresee potential equipment problems. Although PdM is currently used by 41% of manufacturers and is more expensive initially, it is highly cost-effective. According to the U.S. Department of Energy, PdM can save 8% to 12% over preventive maintenance, with the market expected to reach $23.5 billion by 2024.

PdM involves using sensors and software to monitor the condition of in-service equipment, predicting when maintenance will be needed. This allows for maintenance tasks to be performed only as required, potentially reducing costs compared to routine maintenance.

Managing industrial maintenance is a complex task, but by leveraging the right tools, technologies, and low-maintenance components, companies can extend the life and improve the performance of their machinery.

Low- Or No-Maintenance Industrial Machinery was provided by Emerson