Vibration monitoring as part of a predictive maintenance (PdM) programme can be a worthwhile investment for businesses that heavily rely on machinery and equipment. So what return on investment (ROI) can you expect from vibration monitoring? Here are some of the key areas where you can expect to see not only long-term financial gains but sustainability benefits, too.
Early detection of machinery issues
Vibration monitoring systems can detect abnormal vibration patterns in machinery, allowing for early identification of potential faults or malfunctions. By identifying problems at an early stage, businesses can prevent major breakdowns, minimise downtime, and reduce repair costs. The ROI here lies in avoiding expensive repairs, keeping production losses and wastage to a minimum and extending the lifespan of equipment.
Improved maintenance planning
Vibration monitoring data can help optimise maintenance schedules and prioritise maintenance activities based on the actual condition of the equipment. Instead of following a fixed timetable or waiting for breakdowns, businesses can perform maintenance tasks when they’re actually needed. This approach reduces unnecessary maintenance costs and enhances the efficiency of maintenance operations, resulting in higher ROI.
Enhanced equipment reliability and uptime
Regular vibration monitoring enables businesses to identify potential issues before they lead to equipment failure. By proactively addressing problems, companies can significantly reduce unplanned downtime, improve equipment reliability, and increase overall operational uptime. The ROI stems from increased productivity, improved customer satisfaction, and reduced losses due to downtime.
Excessive vibration in machinery often indicates inefficiencies or imbalances that can result in higher energy consumption. Therefore, by continuously monitoring and analysing vibration data, businesses can identify opportunities to optimise equipment performance and reduce energy waste. The ROI here lies in lower energy costs and improved sustainability.
Improved product quality
Vibrations in production machinery can affect the quality of products. By monitoring and controlling vibration levels, businesses can ensure consistent product quality, reduce defects, and minimise scrap or rework. Here, the ROI is delivered through improved customer satisfaction, reduced waste and lower warranty claims.
It’s important to note that the ROI you can achieve will vary depending on factors such as your industry, the specific use case, the scale of operations, and the effectiveness of the vibration monitoring system implemented. So if you want to explore the potential of vibration monitoring for your business, a natural next step is to instigate a comprehensive cost-benefit analysis specific to your business context. This will provide a more accurate estimate of the expected ROI.
Read our case study to find out how one of our clients, a soft drinks manufacturer, was able to save a best-case loss of £480K by monitoring a Krones PET Rinser/ Filler/Capper installed in a UK factory from new in the mid-1990s. And if you’re not sure whether you need vibration monitoring, check out our blog 8 signs you should consider vibration monitoring.