Predictive Maintenance: What It Is, How It Works, and Industrial Use Cases

Modern industry, with its complexity and high production pace, relies heavily on the proper functioning of its equipment. Imagine a halted production line, critical machines out of service, or significant losses of raw materials.

Unfortunately, these scenarios are a reality for many companies that overlook the importance of industrial maintenance. In fact, according to market research, unplanned equipment downtime is estimated to cost an average of USD$125,000 per hour.

At its core, maintenance is the set of actions aimed at ensuring that a company’s physical assets (machines, equipment, facilities) continue to operate efficiently and safely. It is the foundation of productivity, quality, and profitability—preventing unexpected interruptions, extending equipment lifespan, and optimizing operational costs.

Over the years, different maintenance approaches have been developed, each with its own characteristics, advantages, and disadvantages. From simple fault correction to more sophisticated continuous monitoring strategies, the evolution of maintenance reflects the ongoing pursuit of greater efficiency and reduced impact on production.

In this article, we’ll dive into the world of predictive maintenance—a strategy that stands out as one of the most modern and effective. We’ll explore its core concepts, practical implementation, and key benefits, showing how it can transform industrial asset management and drive your company’s success.

What Is Predictive Maintenance?

Predictive maintenance is a technique that uses data and analytics to predict the exact moment a piece of equipment is likely to fail, allowing maintenance to be performed proactively—before the failure occurs. Instead of waiting for breakdowns or performing maintenance at fixed intervals, predictive maintenance continuously monitors asset conditions, identifying signs of deterioration or anomalies that indicate the need for intervention.

According to a study by Data Bridge Market Research, the global predictive maintenance market is projected to grow from $6.72 billion in 2023 to $63.09 billion by 2031.

To better understand predictive maintenance, it’s essential to compare it with other approaches:

What Is Preventive Maintenance?

Preventive maintenance is performed at predetermined intervals, regardless of the actual condition of the equipment. It is based on statistics and manufacturer recommendations to prevent failures. For example, changing a motor’s oil every 5,000 hours of operation is a preventive maintenance action.

While it is better than corrective maintenance, preventive maintenance can lead to the premature replacement of components that are still in good condition or the oversight of issues that develop more rapidly.

What Is Corrective Maintenance?

Corrective maintenance is the most reactive approach. It involves repairing or replacing equipment only after a failure has occurred. While it is sometimes unavoidable, corrective maintenance is generally the most costly and disruptive, as it causes unplanned production downtime and can lead to more severe equipment damage.

When and Why Choose Predictive Maintenance?

The choice of the ideal maintenance strategy depends on several factors, such as the type of industry, equipment criticality, associated costs, and the company’s goals. Predictive maintenance stands out as a strategic option in situations where:

• Failure costs are high: Unplanned downtime can lead to significant production losses, damage to other equipment, safety risks, and contractual penalties.
• Equipment availability is critical: In sectors like mining, oil and gas, and continuous production, even short interruptions can have a massive financial impact.
• Safety is a priority: Failures in critical equipment can endanger workers’ lives and lead to serious accidents.
• The company aims to optimize resources: Predictive maintenance helps reduce maintenance costs, extend equipment lifespan, and minimize resource waste.

It’s important to note that predictive maintenance is not a one-size-fits-all solution. It requires investment in technology, training, and expertise, and its implementation must be carefully planned to ensure a return on investment.

How Predictive Maintenance Works in Practice

Predictive maintenance is based on a continuous cycle of data collection, analysis, and action. The main technologies and steps involved include:

4 Key Technologies Used

1. Sensors: These are the core devices of predictive maintenance. Sensors continuously monitor industrial assets, capturing data on critical variables such as vibration, temperature, pressure, electric current, oil level, ultrasound, and even corrosion.
2. IoT (Internet of Things): Enables interconnectivity between sensors, machines, and digital platforms. With IoT, data is transmitted automatically without human intervention, allowing for remote and real-time monitoring of assets across different locations.
3. Data Analytics: Converts collected measurements into valuable insights. Using specialized software, this data is organized, processed, and correlated to detect trends, identify anomalies, and predict failures. Analysis may include vibration charts, frequency spectrums, and comparisons with historical patterns.
4. Artificial Intelligence (AI) and Machine Learning: Represent the next level of predictive maintenance. These technologies use algorithms that learn from historical and real-time data to recognize complex patterns and predict future events with greater accuracy. Instead of merely reacting to anomalies, systems can suggest corrective actions, prioritize high-risk assets, and even automate maintenance orders.

Basic Operational Workflow

• Data Collection: Sensors continuously monitor equipment conditions, collecting predefined relevant data.
• Data Transmission: The data is transmitted to an analysis system, typically via wireless or cellular networks.
• Data Analysis: The data is processed by software and algorithms that identify patterns, trends, and anomalies.
• Diagnosis and Prognosis: Based on the analysis, a diagnosis of the equipment’s condition is made, along with a prognosis estimating the remaining time before failure.
• Maintenance Planning: The maintenance team receives alerts about the need for intervention, allowing them to plan activities efficiently and minimize production impact.
• Maintenance Execution: Maintenance is performed at the optimal time, preventing unexpected failures and optimizing resource use.
• Results Evaluation: Maintenance outcomes are evaluated to assess the effectiveness of the strategy and identify opportunities for improvement.

Examples of Predictive Maintenance in Industry

Predictive maintenance has applications across various industrial sectors, delivering significant benefits for different types of equipment:

• Electric Motors: Monitoring vibration and temperature helps detect imbalances, misalignments, looseness, and other issues that could lead to motor failure.
• Pumps: Vibration, pressure, and flow analysis assist in detecting cavitation, rotor wear, blockages, and other problems that affect pump performance and lifespan.
• Compressors: Monitoring temperature, pressure, and vibration enables the detection of leaks, valve wear, lubrication issues, and other failures that can compromise compressor efficiency and safety.
• Bearings: Vibration and temperature analysis is essential for detecting wear, looseness, and other issues that could lead to catastrophic bearing failure.
• Turbines: Predictive maintenance is critical for turbines, where failures can have severe consequences. Monitoring vibration, temperature, pressure, and other parameters helps identify early-stage issues, preventing unplanned downtime and accidents.

Industries That Frequently Use Predictive Maintenance

• Mining: Predictive maintenance is essential to ensure the availability of heavy and critical equipment such as excavators, trucks, and mills, which operate under harsh conditions and have high downtime costs.
• Agroindustry: Predictive maintenance helps optimize the operation of agricultural machinery and processing equipment, preventing production losses and ensuring product quality.
• Oil and Gas: Predictive maintenance is crucial on oil platforms and in refineries, where failures can have catastrophic environmental, safety, and financial consequences.
• Manufacturing: In automated production lines, predictive maintenance ensures operational continuity, avoiding unplanned downtime and productivity losses.

Success Story Example

Dynamox offers asset monitoring solutions that enable efficient and accessible implementation of predictive maintenance. Our wireless sensors collect data on vibration, temperature, and other parameters, transmitting the information to an analytics platform that generates valuable insights for the maintenance team.

One success story is our monitoring solution for off-road vehicles, which allows mining and construction companies to track the condition of their equipment in real time, predict failures, and optimize maintenance.

Predictive Maintenance KPIs

To ensure the effectiveness of a predictive maintenance strategy, it is important to continuously monitor key maintenance indicators. Some metrics evaluate the operational condition of individual assets, while others provide an integrated view of overall plant performance.

These insights support more accurate analyses and inform both technical and strategic decision-making by managers and analysts:

MTBF (Mean Time Between Failures)

MTBF measures the average time between equipment failures. A higher MTBF indicates greater reliability and fewer failures. Predictive maintenance helps increase MTBF by identifying and addressing issues before they lead to failure.

MTTR (Mean Time to Repair)

MTTR measures the average time required to repair equipment after a failure. A lower MTTR indicates greater maintenance efficiency. Predictive maintenance helps reduce MTTR by enabling advance planning of maintenance activities, ensuring the availability of parts and resources.

Maintenance Cost per Asset

This indicator measures the total maintenance cost divided by the number of assets. Predictive maintenance helps reduce the maintenance cost per asset by preventing emergency repairs, extending equipment lifespan, and optimizing resource usage.

How to Interpret and Act on the Data

Correctly interpreting maintenance indicators is essential for making strategic decisions and optimizing operations. For example:

• If MTBF is decreasing, it may indicate that equipment is deteriorating faster than expected, suggesting a need to review maintenance strategies or invest in new equipment.
• If MTTR is high, it may signal that the maintenance team needs more training, better tools, or additional resources to perform repairs more efficiently.
• If maintenance cost per asset is rising, it may indicate that equipment is becoming more expensive to maintain, prompting an evaluation of the operation’s economic viability.

Dynamox offers solutions that simplify the collection, analysis, and visualization of maintenance indicators, providing valuable insights for decision-making.

8 Benefits of Predictive Maintenance

Adopting predictive maintenance brings a wide range of benefits to companies, including:

1- Reduced Operational Costs

Predictive maintenance significantly lowers operational costs by preventing unplanned downtime, which often involves high expenses for emergency labor, component replacement, and lost production. It also optimizes the use of resources such as materials and energy, minimizing waste and making operations more sustainable and efficient.

2- Decreased Production Losses

With the ability to predict failures and act before they occur, predictive maintenance allows interventions to be scheduled during low-demand periods or planned maintenance windows. This means fewer unexpected interruptions, greater production stability, and fewer missed delivery deadlines.

3- Optimized Use of Resources (Machines and People) 

By basing maintenance actions on real data and observed trends, maintenance teams can be allocated more strategically. This eliminates rework and unnecessary maintenance, freeing up personnel for higher-value tasks and improving overall maintenance management efficiency.

4- Maximum Productivity Throughout the Asset Lifecycle

Predictive maintenance ensures that industrial assets operate near their optimal performance. Keeping equipment in ideal operating condition throughout its lifecycle means higher productivity, fewer failures, and greater profitability.

5- Increased Equipment Availability

One of the most important maintenance KPIs, equipment availability, is directly impacted by predictive maintenance. By continuously monitoring operating conditions, teams can act quickly and proactively, avoiding unexpected downtime and maximizing machine uptime.

6- Failure Predictability

A major advantage of predictive maintenance is the ability to anticipate failures based on concrete data such as vibration, temperature, and wear patterns. This predictability allows maintenance teams to plan ahead, schedule interventions, order spare parts, and minimize the impact of potential failures.

7- Extended Equipment Lifespan

By detecting issues in their early stages—often imperceptible to the naked eye or without proper monitoring—predictive maintenance enables corrective actions that prevent failure escalation. This extends asset lifespan, reduces the need for frequent replacements, and improves return on investment.

8- Improved Workplace Safety

In critical industrial environments (such as oil and gas or mining, where there is a risk of explosions), equipment failures can pose serious threats to worker safety and plant integrity. Overheated motors, weakened structures, or leaks can lead to major accidents.

Predictive maintenance acts as an additional layer of protection, reducing the likelihood of catastrophic failures and ensuring a safer work environment for all employees.

The Future of Maintenance Is Predictive

Predictive maintenance is not just a trend—it is a vital strategy for companies aiming to optimize operations, reduce costs, and increase competitiveness. By leveraging advanced technologies and data analytics, predictive maintenance enables a shift from reactive to proactive maintenance, anticipating failures and enabling smarter actions.

In today’s industrial landscape—where competition is fierce and technology evolves rapidly—predictive maintenance is becoming increasingly indispensable. Companies that adopt this strategy will be ahead of the curve, ready to face future challenges and achieve long-term success.

Dynamox is a leader in asset monitoring solutions, offering the tools and expertise needed to implement predictive maintenance efficiently and effectively.

With multinational certifications:

• ANATEL (Brazil), 
• FCC (USA), 
• CE (European Union),
• IC (Canada), 
• RCM and ACMA (New Zealand and Australia).

We are a global reference in industrial reliability and safety. Our mission is to make your industry safer and more productive than it was yesterday.

Enable smart maintenance, reduce costs, and maximize asset availability. Discover Dynamox solutions and speak with a specialist.