Moving From Reactive to Predictive Maintenance in Your Food Facility

As mentioned earlier, the most common PdM monitoring technologies are vibration analysis, infrared thermography, ultrasonic inspection, and oil analysis. In most facilities, one or two of these technologies predominate; for example, machines with fans and high-speed moving parts will benefit from vibration analysis, while electrical equipment requires advanced temperature monitoring. Failure mode and effects analysis is helpful in determining statistical norms and thresholds for machines, subsystems, and components.

Data from PdM activity must be tightly integrated into maintenance work processes. CMMS or other work order system is the appropriate destination to ensure that repair/replace work is done in a timely manner. The most advanced PdM program will be of no value if a machine experiencing imminent failure is not serviced promptly.

Finally, it’s important to track and document results. Comparing program progress against baseline data will demonstrate performance, justify cost, and uncover opportunities for further improvement. (Be sure to share results with senior management as well as maintenance and operations staffs.)

Moving from a reactive maintenance mindset to one that is predictive in nature takes time. It also requires C-level commitment since a culture shift in your processing facility will be needed. You can shorten your learning curve by researching models and practices appropriate to your situation; chances are good that no matter how unique your operation seems, someone has solved similar challenges before. Another alternative is to work with a strategic service partner skilled in PdM—someone with the necessary personnel, best practices, and technology to implement your program in the shortest possible time.

While many food manufacturers are still wrestling with the idea of predictive controls, PdM can take you a long way toward achieving the FDA’s food safety requirements. What’s more, the productivity benefits and cost savings eventually more than make up for the investment in PdM.

As you make these critical decisions, ask yourself what is the cost of inaction. Recalls are expensive—and no amount of production efficiency is worth it if the product can’t be safely consumed. Whether designed internally or strategically sourced, PdM is essential to FDA mandates in particular—and food safety in general.

Martin is director of operations, industrial parts services for Advanced Technology Services, Inc. Reach him at [email protected].