Reverse Engineering for Planned Preventative Maintenance (PPM)

What is Planned Preventative Maintenance (PPM)?

Planned Preventative Maintenance (PPM) is also provided by our sister company, PES Scanning. Planned Preventative Maintenance is a scheduled maintenance programme designed to maintain high value assets.

PPM is not the lowest cost maintenance programme. It is usually built into the operational plan as an insurance or preventative programme, to reduce the risk to high value manufacturing processes or operations that rely on the reliability of machinery.

The cost of the PPM is off-set by the fact that if the machinery fails unexpectedly the ‘down time cost’ due to lost production or interruption of critical operations, such as in the maritime environment, would far exceed the maintenance programme costs.


Where can reverse engineering support the PPM programme?

Legacy Equipment

Many manufacturing businesses still operate machinery that was built in the ‘pre-digital’ era.  These machines are often a bespoke design for a specific operation or no longer in production, with spares either scarce or unavailable. The equipment though old is however usually very effective and efficient, and replacement would be incredibly expensive and potentially not viable, including the ‘down time’ of the operation during replacement.

Many operators do not realise that with modern data capture technologies, such as 3D optical scanning – blue light scanning and CT- scanning, parts can be recreated as 3D CAD models to ‘reverse engineer’ and digitise either major components or complete assemblies of equipment with incredible levels of fidelity to the original part.

This data can then be used to manufacture replacement parts or spares.  Through the use of these technologies, we can potentially extend the life of the equipment indefinitely or to the point when investment in new equipment becomes a more viable option.

These technologies are not necessarily cheap, however if the correct technology is applied to deliver a solution, the savings to a company in production costs and the reduction in risk of catastrophic failures, and therefore asset replacement, make this a viable and cost effective insurance.

 Spares and Part Replacements in new out of warranty equipment

Challenges faced when replacing parts of equipment:

•  Long lead in periods for delivery.
•  High cost of spares due to the manufactures’ monopoly on the equipment.
•  Large cost of spares due to a whole assembly having to be purchased rather than just replacing the part that is defective.

We can capture the data from original parts and hold that data in a digital archive until such point as the client requires it. We can then use this data to create 3D CAD models and manufacturing drawings and then manufacture a new part at a potentially lower cost and with shorter lead times to meet the clients’ deadline.. If you wish the parts can also be optimised to improve their performance for the job you require or increase life and efficiency.

Equipment Optimisation

This is the process of improving the performance of a component or equipment where digital data and drawings are inaccessible or simply do not exist. We would therefore have to capture the part’s geometric data to start the optimisation process.

If you would like to know more about the Planned Preventative Maintenance (PPM) process and how it can be applied as a solution for your business, then please contact us to discuss your requirements. If you would like to discuss your particular project or wish to understand how reverse engineering can offer you a solution then please contact us for a chat or drop us an e-mail with your enquiry. We will consider any project no matter how small or large.

Read more about Reverse Eng for PPM here.

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The team have provided solutions for UAV composite propellers, the F-35 (Joint Strike Fighter) project, and reverse engineering projects, with our blue light scanning service.

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