Top Predictive Maintenance Challenges & How to Overcome Them

Predictive maintenance (PdM) is a powerful tool to help businesses keep their equipment running smoothly and avoid costly downtime. However, implementing a PdM program is not without its challenges. In actuality, this maintenance strategy requires much more support than just the initial investment in hardware and software. To achieve the best results, it will be necessary to continuously monitor, train, and make data-driven improvements. 

So today, we will discuss some of the challenges a business could face when implementing a predictive maintenance program. After introducing those challenges, we will discuss how LLumin’s Computerized Maintenance Management System (CMMS+) is a one-stop solution to solve the top predictive maintenance challenges.

The Top Predictive Maintenance Challenges

PdM has emerged as one of the most powerful maintenance solutions available on the market today, with usage projected to rise dramatically over the next ten years. However, to get the best return on investment, you will need to overcome inherent complex challenges that come along with managing PdM over time.

Some of the most significant challenges are its high initial costs, complex data management and analysis needs, and even privacy concerns. Further, employee resistance to change and the ongoing need for continuous improvement can pose serious barriers to success if not properly addressed.

Below, we’ve summarized the top predictive maintenance challenges. Then, following a review of these challenges, we’ve highlighted how LLumin’s advanced CMMS+ can play a critical role in helping you overcome them.

Challenge	Description
Investment and Execution	Establishing and implementing the program, including equipment and employee training, can be expensive.
Data Challenge	Difficulty managing and analyzing the massive amounts of data required for predictive maintenance, including data collection, storage, and analysis.
Adoption Challenge	Employees used to traditional maintenance methods are resistant to change, and implementing the program across departments and teams is challenging.
Privacy and Security Concerns	Concerns about data breaches and unauthorized access are among the risks associated with storing and transmitting sensitive data.
Continuous Improvement	Difficulty in ensuring that the program evolves and improves over time, as well as challenges with implementing changes and tracking results.

Below we will dive further into these predictive maintenance challenges and offer initial solutions to solve them.

1. Initial Investment and Execution

When it comes to implementing a predictive maintenance program, it can be costly. To get the most out of your program, you’ll need to invest in the right sensors, data storage and analysis tools, and possibly even hire specialized staff. All of this can add up, and it’s critical to budget accordingly to get the most out of your investment.

Cost is also only one part of the equation. Your new program will need to be carefully planned and coordinated, which may entail creating a maintenance schedule, establishing benchmarks, monitoring key performance indicators (KPIs), and conducting extensive machine-level data analysis. This process must be set up correctly from the beginning and continue to be consistently dependable through start-date and beyond in order to benefit the most from PdM.

2. The Data Challenge

Even with a group of skilled data analysts on your side, managing sizable amounts of machine-level data can be challenging. To get the most out of a PdM program, continuous large-scale data collection and analysis from machine-level sensors and other sources is required. Data management will be difficult, particularly if dispersed among disparate systems.

Another issue is data quality, as inaccurate or incomplete data can result in erroneous predictions and false alarms. It will be crucial to have a system in place to manage data efficiently and guarantee its completeness and accuracy. You must also take into account your needs for data storage and security.

3. The Adoption Challenge

PdM is not just about cutting-edge technology. It’s crucial to keep in mind that your entire maintenance staff will need to support it. Engaging employees in your new implementation project and seeking their support can be one of the biggest PdM challenges. And if adequate training is not provided to employees as your implementation project moves forward, change may not be welcomed.

The adoption challenge can be more effectively overcome with skill assessments, hands-on training with new tools and software, and employee feedback. Take your time with this process to ensure your program is as successful as possible.

4. Privacy and Security Concerns

Large-scale data collection, transmission, and storage inevitably raises concerns regarding security and privacy. It will be crucial to ensure that your data is transmitted and stored securely and that only authorized individuals have access. It only takes a few minutes for data to end up in the wrong hands and cause significant costs, downtime, and damages.

Make a long-term commitment to regularly monitoring your data security protocols and staying up to date with the most recent protections. Take the time to understand the regulations that apply to your particular industry and program to ensure you comply with current standards. By doing this, you can reduce your exposure to legal and financial repercussions and safeguard your reputation.

5. The Need for Continuous Improvement

A predictive maintenance program is not a set-it-and-forget-it solution. It requires continuous improvement, monitoring, and refinement to remain effective. This includes updating predictive models, analyzing data for new trends, and changing workflows and processes as needed.

To overcome these challenges, work with an experienced partner who can provide guidance and support throughout the implementation process. A comprehensive and advanced system, like LLumin’s CMMS+ software, can help resolve many of these challenges, including data management, adoption, and continuous improvement.

Use LLumin’s Advanced CMMS+ to Overcome Predictive Maintenance Challenges

Working with the right CMMS solution will be an invaluable tool for businesses looking to implement a new PdM project. When equipped with the right features and with the right training and support, a CMMS can help you overcome many of the top predictive maintenance challenges, from data management to ensuring employee adoption and buy-in.

LLumin’s CMMS+ offers a secure, centralized platform for data storage and analysis, powerful reporting and predictive analytics tools, a user-friendly interface, and exceptional customer support, including ongoing training, to ensure that all users are ready to maximize the ROI of their new PdM program. 

Challenge	How LLumin’s CMMS+ Can Help
Investment and Execution	LLumin automates tasks, tracks maintenance costs, and provides powerful reporting and analysis tools to maximize ROI.
Data Challenge	Provides a centralized repository for data storage and analysis, as well as robust reporting and analysis tools for identifying trends and patterns in data.
Adoption Challenge	LLumin has an easy-to-use interface, intuitive workflows, and the training and support you need to help employees navigate the CMMS+ and your new PdM program.
Privacy and Security Concerns	Robust access controls, data encryption, audit trails, and logging features to track access to your data.
Need for Continuous Improvement	Advanced reporting and analysis tools, as well as workflows and processes to implement change and track maintenance KPIs, are available to drive continuous improvement.

Partner With LLumin to Support the Best ROI on PdM

LLumin’s advanced CMMS+ is 100% HTML5 compliant, browser independent, and mobile-friendly. LLumin can help take your PdM project to new heights by streamlining work order management, easily tracking KPIs, and gaining access to highly-accurate insights needed to optimize asset performance and fully extend equipment lifespans.

At LLumin, we focus on excellent customer service to ensure your PdM implementation project is successful and timely. Our implementation team will tailor CMMS+ to support your company’s specific goals and business processes, providing you with an implementation plan and a support team to accelerate and guide your digital transformation. 

If you are looking for a cutting-edge CMMS+ with a rapid implementation process and  expert customer support staff, then LLumin is a perfect fit. Join the many satisfied customers who have experienced the benefits of LLumin’s CMMS+ software today.

Getting Started With LLumin

LLumin develops innovative CMMS software to manage and track multiple assets and facilities for industrial plants, municipalities, utilities, fleets, and facilities. To get started and improve your CMMS ROI, we encourage you to schedule a free demo or contact the experts at LLumin to see how our software can help you reach your management goals.