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Predictive Maintenance and Optimisation of Preventative Maintenance Regime


The industrial landscape in today’s world is rapidly evolving, thus, maintaining and optimising equipment is critical to ensure smooth operations and minimise downtime. Predictive maintenance and the optimisation of preventative maintenance regimes maintenance essential resources to enable businesses to proactively address maintenance issues before they escalate into costly problems. As part of the LotusWorks Reliability Engineering programme, the continuous monitoring of the health and performance of machinery, allows businesses to detect potential issues early, allowing them to schedule maintenance activities strategically, thus, leading to cost savings.  


predictive maintenance and preventative maintenance equipment

Predictive Maintenance (PdM)

Predictive Maintenance (PdM) also known as Condition Based Maintenance (CBM) is an essential tool for the pharmaceutical industry, providing the ability to monitor equipment in real-time, identify potential problems, and schedule maintenance activities proactively. With the implementation of PdM, pharma companies can reduce the risk of unplanned downtime, optimize maintenance activities, and improve overall equipment effectiveness. For example, LotusWorks provides a complete Predictive Maintenance Program with state-of-the-art equipment, enabling our clients to reduce unforeseen downtimes and plan equipment swap-outs that best suit plant operational needs. 

Our team in the pharmaceutical plant has identified several infant mortality cases with replacement equipment, wrong installation by OEM, and poor repairs made by local 3rd party providers. By detecting these issues early, we were able to save our client significant costs in terms of warranty claims and avoid unplanned downtime. PdM is a critical component of a robust reliability program, and LotusWorks is committed to providing our clients with the latest technologies and expertise to optimize their operations and maximize productivity. 

Optimisation of the Preventive Maintenance Regime

Performing PM regime optimization is critical to ensure that maintenance activities are aligned with the needs of the plant and that resources are utilized efficiently. The PM optimization exercise involves analysing the effectiveness of existing PM activities, identifying areas for improvement, and implementing changes to optimize maintenance activities. This exercise is essential for reducing maintenance costs, improving equipment reliability, and maximizing equipment uptime.  

 By optimizing the PM regime, companies can minimize the need for corrective maintenance, reduce equipment downtime, and improve overall equipment effectiveness. This exercise also helps to ensure that the maintenance program is aligned with the plant’s operational needs and is carried out in a cost-effective manner. Ultimately, performing PM regime optimization helps companies achieve greater productivity, reduce maintenance costs, and maximize their return on investment. 

In a pharmaceutical plant, our team identified oil testing as an area for improvement in the PM program. Although oil testing is a standard PM activity, it incurred additional costs in terms of testing and man-hours spent in collecting and posting samples, followed by additional man-hours spent by SMEs in going through the reports. The actual impact of these steps was found to be far less compared to the time being spent on the whole activity. As a result, our team proposed replacing the regime of oil analysis with oil replacement, which would be more cost-effective and reduce man-hours 

predictive maintenance

Oil replacement would involve draining and replacing the oil after a certain period, based on the equipment and operating conditions. This approach would eliminate the need for oil testing, which would reduce testing costs and save man-hours. Additionally, it would help prevent potential equipment failures and extend equipment life by ensuring that the oil is in optimal condition. The PM optimization exercise helped the pharmaceutical plant reduce maintenance costs and improve overall equipment effectiveness by ensuring that PM activities were optimized and aligned with plant operation. 


LotusWorks Reliability Engineering Programme emphasizes the pivotal role of predictive maintenance and the optimization of preventative maintenance regimes in ensuring seamless operations, minimizing downtime, and prudent resource utilization within the evolving industrial landscape. By leveraging predictive maintenance’s real-time monitoring and proactive issue resolution, businesses can enhance equipment effectiveness while LotusWorks’ commitment to cutting-edge solutions underscores their dedication to operational optimization. Concurrently, the strategic overhaul of preventive maintenance, as exemplified by the transition from oil testing to oil replacement, showcases the tangible benefits of aligning maintenance activities with plant needs, yielding reduced costs, improved reliability, and heightened productivity. This integrated approach underscores how predictive maintenance and optimized preventive strategies collectively form the bedrock of sustained operational excellence, adeptly navigating industry dynamics and magnifying overall returns on investment. 

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Travis Miller


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