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When the thermal images indicate an overheating bearing, generate a maintenance order to replace or lubricate the bearing housing and reduce or eliminate the possibility of costly engine failure.

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By monitoring equipment performance and scheduling maintenance when needed, these facilities reduce the likelihood of unplanned downtime due to equipment failure, spend less on "reactive" maintenance fees and equipment repair costs, extend the lifespan of machine assets, and further maximize maintenance and production.

Here's the trick: To actually save money, predictive maintenance should not create excessive additional maintenance efforts.

Keep a record of machine asset availability, production output, and the distribution of maintenance dollars and total maintenance costs over time.

Those numbers will help you calculate the return on your thermal imaging and maintenance investment.

Studies by the Federal Energy Management Program (FEMP), estimate a properly functioning predictive maintenance program can provide a savings of 30% to 40% over reactive maintenance.

Other independent surveys indicate that, on average, starting an industrial predictive maintenance program results in the following savings: To calculate the savings at your facility, start by estimating the costs of unplanned equipment failures.

The goal is to transition maintenance resources away from emergency repairs and into scheduled inspections of key equipment.

Inspections take less time than repairs, especially if done with a thermal imager.

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Either way, an infrared imager can diagnose the problem.

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