Predictive maintenance annual cost

The overall benefits of predictive maintenance management have proven to substantially improve the overall operation of both manufacturing and process plants. In all surveyed cases, the benefits derived from using condition-based management have offset the capital equipment cost required to implement the program within the first three months. Use of microprocessor-based predictive maintenance techniques has further reduced the annual operating... 

Productivity improvements can often be achieved with minimal investment. For example, a pump in production-critical service may fail once every 3 months. If each pump failure leads to production losses of 15,000, then the annual cost of this problem is 60,000. Investigation into the pump failures shows that the breakdown rate could be greatly reduced where a preventive maintenance system was to be implemented, so that problems can be addressed before the pump actually fails. It is predicted that the new failure rate will be once per year, equivalent to a loss of 15,000 per year. Hence the annual savings that flow from the preventive maintenance program are 45,000. If the preventive maintenance system for that pump costs say 10,000 to implement and 5,000 per year to run, then the net savings over a period of 5 years is 190,000 (ignoring the discounted value of money), and the return on investment is very high indeed. 

When these factors are considered, cost comparisons bear little resemblance to first costs. Table 11 presents a typical analysis of comparative costs for alternative materials when based on return on investment. One difficulty with such a comparison is the uncertainty associated with estimated life. Well-designed laboratory and plant tests can at least give order-of-magnitude estimates. Another difficulty arises in estimating the annual maintenance cost. This can only be predicted from previous experience with the specific materials. 

As noted earlier, an accurate selection of sources requiring control can best be achieved through the application of the Air Quality Display Model for each AQCR of interest. It is estimated that the total one-time cost of such an exercise at a level of accuracy necessary to predict source sulfur dioxide control requirements for each of the 245 AQCR s would be about 10 million with an additional annual maintenance cost of 500 thousand to allow for emission inventory changes. For comparison. 

With the corrective actions taken to date, it has been possible to increase by 1.1% the global zinc extraction. The global zinc recovery has increased by 2.3% and it is predicted that with the better control of the circuit and with an optimal residue wash, the proposed goal of 94.5% zinc recovery will be easily obtained during this year. The success of the improvement project will more than justify its cost of 6.6 million U.S. dollars, with an annual production increase of 2,500 tonnes of refined zinc. As well, a decrease in maintenance cost is expected along with an increase in the availability of the equipment because of the substitution of filtration equipment and the operation of the gypsum removal step. 

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