{"id":10310,"date":"2025-05-18T07:51:44","date_gmt":"2025-05-18T14:51:44","guid":{"rendered":"https:\/\/www.qad.com\/blog\/?p=10310"},"modified":"2025-07-08T17:24:06","modified_gmt":"2025-07-09T00:24:06","slug":"what-is-predictive-maintenance-pdm","status":"publish","type":"post","link":"https:\/\/www.qad.com\/blog\/2025\/05\/what-is-predictive-maintenance-pdm","title":{"rendered":"What is Predictive Maintenance (PdM)?"},"content":{"rendered":"

[vc_row][vc_column][vc_single_image image=”10311″ img_size=”full”][vc_column_text]Updated: May 18, 2025
\nOriginally Published: Jul 20, 2022<\/small><\/em><\/p>\n

Several years ago, if you had a preventive maintenance program, you were considered to have a solid grasp on maintaining your equipment. As technology has evolved and the ability to collect and analyzedata, including agentic AI,has become more prevalent in recent years, having a predictive maintenance plan is now within reach to a broader set of\u00a0 manufacturers. Let\u2019s dive into what predictive maintenance is and how a smart strategy combined with the right software can save your organization significant time and money.\u00a0<\/span><\/p>\n

What is Predictive Maintenance?<\/span><\/h2>\n

Despite the similar name, predictive maintenance (PdM) differs from preventive maintenance. When you adopt a preventive maintenance strategy, you take preventive measures to keep your equipment in good condition so you don\u2019t end up with an unexpected breakdown that leaves you with equipment downtime and costly repairs. While preventive maintenance can definitely help you improve operations, predictive maintenance takes being proactive to the next level.\u00a0<\/span><\/p>\n

Predictive maintenance software allows manufacturers to collect and track equipment so granularly that you can precisely pinpoint when a piece of equipment will require certain maintenance. Over time, this software forms a data story about each piece of equipment so that it provides the insight to help you schedule maintenance at the most convenient and cost-efficient moment. You\u2019ll be able to correct issues before equipment is compromised, optimizing your equipment\u2019s lifespan.\u00a0<\/span><\/p>\n

Predictive maintenance software utilizes nondestructive testing methods such as acoustic, corona detection, infrared, oil analysis, sound level measurements, vibration analysis and thermal imaging. These technologies work together to gather real-time data that gives you extensive visibility into the condition and performance of your equipment.\u00a0<\/span><\/p>\n

The typical process flow for a predictive maintenance program looks like:<\/span><\/p>\n

    \n
  1. Determine equipment and failure mode to be monitored.<\/span><\/li>\n
  2. Establish frequency.\u00a0<\/span><\/li>\n
  3. Monitor condition.<\/span><\/li>\n
  4. Issue report.<\/span><\/li>\n
  5. If there is no abnormality, return to Step 3. If there is, continue to Step 6.<\/span><\/li>\n
  6. Create a work order.<\/span><\/li>\n
  7. Plan a work date.<\/span><\/li>\n
  8. Ensure parts and labor are available.\u00a0<\/span><\/li>\n
  9. Perform repair.<\/span><\/li>\n
  10. Close work order and return to Step 3.<\/span><\/li>\n<\/ol>\n

    Predictive Maintenance vs. Inspection for Defects<\/span><\/h2>\n

    There has been a lot of debate in the manufacturing world about how best to identify defects so that the process of creating work orders, ordering parts, and scheduling and completing the work happens smoothly before reaching a high probability of equipment failure. Let\u2019s look at a few popular inspection techniques.\u00a0<\/span><\/p>\n

    Sensory Inspections<\/span><\/h3>\n

    Traditional sensory inspections have long been used to detect potential equipment issues. A technician would go around and use sight, sound and touch to identify any changes since the last inspection and note any problems. This would be investigated and work would follow if needed. While it\u2019s nice to have actual eyes and ears on the floor, this method runs the risk of missing quite a bit. Sensory inspections can typically only recognize obvious problems that are either severe or have been building for a while and are now hard to overlook. A sensory-only inspection is likely to miss more subtle issues or catch problems when they first begin, which can result in a lot of wasted time, a more expensive repair and inconvenient equipment failure.\u00a0<\/span><\/p>\n

    Enhanced Sensory Inspections<\/span><\/h3>\n

    Enhanced sensory inspections do improve upon the traditional, consisting of both a sensory inspection and a quantitative measurement with condition-monitoring characteristics. This method uses spot radiometers, strobe lights, handheld vibration pens and ultrasonic meters to identify defects further up the P-F curve. While this is a step up from basic sensory inspections, these tools still shouldn\u2019t replace a comprehensive condition-monitoring program.\u00a0<\/span><\/p>\n

    Quantitative Inspections<\/span><\/h3>\n

    This type of inspection can certainly provide valuable information when it comes to generating and analyzing data. These measurements provide useful data to the planner and engineer and help determine the need for maintenance attention. A quantitative inspection procedure details limits and typically expected measurements. It should have the minimum, maximum and typical values, with conditional tasks defined for when limits are exceeded. A quantitative inspection performed at the proper inspection frequency, however, will rarely have a measurement that exceeds the limits.<\/span><\/p>\n

    Predictive Maintenance<\/span><\/h3>\n

    Predictive maintenance, sometimes known as condition monitoring, uses statistical process control or equipment performance analytics to detect and eliminate equipment defects early. This method is conducted while equipment is in normal operation with little to no process interruption. Utilizing tools such as vibration analysis, infrared thermography, motor circuit analysis, quantitative downtime-event data, and others allows teams to find defects often missed by other inspection techniques. Manufacturers who adopt a predictive maintenance program experience far fewer equipment issues and avoid preventable downtime and costly repair.\u00a0<\/span><\/p>\n

    Types of Predictive Maintenance Technologies<\/span><\/h2>\n

    Predictive maintenance and manufacturing uses several types of technologies. See common predictive maintenance tools below.\u00a0<\/span><\/p>\n

    Vibrational Analysis<\/span><\/h3>\n

    Machine Speed: High | Machine Type: Mechanical | Cost: Medium<\/span><\/i><\/p>\n

    A machine in peak condition exhibits a particular vibration pattern. A vibrational analysis allows a technician to monitor a machine\u2019s vibrations by using a handheld analyzer or real-time sensors built into the equipment. For plants with high-rotating machinery, vibrational analysis is the go-to means of analysis. Given how long it\u2019s been utilized, it\u2019s more cost-effective, and it can detect looseness, imbalance, misalignment and bearing wear.\u00a0<\/span><\/p>\n

    Acoustical Analysis (Sonic)<\/span><\/h3>\n

    Machine Speed: Low, High | Machine Type: Mechanical | Cost: Low<\/span><\/i><\/p>\n

    Using acoustic technologies, teams can detect gas, liquid or vacuum leaks in equipment on a sonic or ultrasonic level. An acoustical analysis is less expensive to implement and is used for low- and high-rotating machinery. It\u2019s similar to vibrational analysis; however, acoustical analysis is meant more for lubrication technicians and focuses on proactive lubrication measures.\u00a0<\/span><\/p>\n

    Infrared Analysis<\/span><\/h3>\n

    Machine Speed: Low, High | Machine Type: Mechanical, Electrical | Cost: Low<\/span><\/i><\/p>\n

    Infrared technologies are widely used in predictive maintenance. Using IR cameras, teams can detect high temperatures (hotspots) in equipment likely generated from worn components. An infrared analysis doesn\u2019t depend on an asset\u2019s rotational speed or loudness, making it suitable for a variety of equipment types.\u00a0<\/span><\/p>\n

    Automated Downtime Recording and Categorization<\/span><\/h3>\n

    Down time duration | Event Frequency \/ Downtime causation code | Cost: Low<\/span><\/i><\/p>\n

    Predicting future maintenance requirements is often dependent on understanding recent trends in equipment performance. Legacy approaches often made attempts at capturing this data in log books or in isolated SCADA systems. The advent of Industry 4.0 and live connected worker software has provided a more automated and uninvasive opportunity to capture this data and ultimately add additional analytical input to predictive maintenance efforts. First hand data from shop floor operators provides a critical element to effective equipment maintenance.<\/span><\/p>\n

    Industries Utilizing Predictive Maintenance<\/span><\/h2>\n

    Predictive maintenance software benefits a variety of industries. Some of the top growing fields utilizing predictive maintenance strategies include:<\/span><\/p>\n