Historically, maintenance strategies for critical systems have relied heavily on fixed schedules, called preventive maintenance. Although this is useful, it follows an arbitrary schedule, i.e. over-service or ignoring the actual needs of the equipment. “too frequent” maintenance (unnecessary, also results in avoidable downtime and waste of valuable resources. On the other side, spectrum is reactive maintenance – only resolves the problem after problems occur, resulting in system failure at the most inappropriate moments. Relying on any maintenance schedule that does not include real-time conditions means missing out on key metrics.
There is nothing more important in the biopharmaceutical industry. Misplaced maintenance translates into wasted time and higher costs when storing life-saving products, which can damage the effectiveness and safety of drugs, vaccines or medical products. When refrigeration equipment is critical to the biopharmaceutical industry, its consequences are beyond the immediate scope. It harms community health and creates ripple effects through global supply chains. Predictive maintenance can protect these operations.
Predictive maintenance technology – a new standard, a new era
Predictive maintenance (PM) utilizes key technologies such as wireless IoT sensors, machine learning, AI and advanced analytics to continuously evaluate device health. These systems monitor temperature, pressure, electrical, vibration and other key indicators in real time. This data is analyzed to detect changes in established benchmarks and other abnormalities, so that only prioritizing repairs are performed on required equipment before inevitable failures occur.
PM is not only convenience, it is a new way to ensure operational excellence in key industries such as healthcare, biopharmaceuticals and life sciences. It replaces any time-based schedule with insight based on real conditions. As a result, downtime is minimized and equipment life and efficiency are maximized.
If you equip the environmental room (a life-saving vaccine for housing) with a strategically placed sensor, you can use this data to detect subtle performance changes, an early indicator of future failure. These insights allow you to detect that they escalate in a threat to the room environment. With long lead times, maintenance can be actively arranged without interrupting operations, thereby avoiding damage to valuable products and delivery delays. This ability to expect rather than react to action sets PM apart and establishes it as the gold standard in the industry with life-saving products.
Maximize equipment uptime and operational efficiency
Organizations relying on refrigeration systems know that equipment uptime is directly related to operational efficiency and service quality. Predictive maintenance can reduce unexpected failures and make things run efficiently, making scheduling service intervention easier. It allows the team to focus on positive improvements during regular hours rather than rushing to deal with emergencies within odd hours.
PM also minimizes the need to retain additional equipment in emergencies. This reduces costs while optimizing resource usage, so companies can make the product go smoother. These tools allow organizations to better manage their systems, adjust their energy usage more effectively and reduce waste, resulting in financial savings and moving towards sustainability goals.
Protecting and saving products
Predictive maintenance plays an important role in protecting life-saving products. Vaccines and other drugs are tested for stability and must be stored in the chamber and kept within a specific temperature range over time. If the temperature is not up to standard, the result may bring the product to market.
In the afternoon, make sure these rooms are always running optimally by providing early warnings about mechanical issues that end up threatening the product. This maintains product integrity and ensures protection of public health.
For healthcare providers, regulators and other key stakeholders, this trust knows that there is a reliable solution that emphasizes control, precision and accountability. It enables organizations to gain trust in their communities and in their participating ecosystems.
Lessons learned
The shift to PM practice represents the responsibility of the storage facility to protect life-saving products and the people they serve. In the past, arbitrary maintenance schedules and planned downtime were necessary expenses. Now, we have different thinking and working tools.
Adopting forecasting practices requires up-term investment, adjustments to workflows, and how maintenance is handled and when to change. However, the initial cost is not helpful compared to the cost of responding to emergencies – think of disruptive operations, late-night calls for support, piles of paperwork, and possible product losses. Developing a clear roadmap can help ensure a smooth transition to predictive practices and get the most value from it.
future
Predictive maintenance is about optimizing operations, fulfilling our role as managers of critical resources, and prioritizing the well-being of communities that rely on them. This technology is future-proof and can protect the basic biopharmaceutical process and ultimately save lives. The same is true of the possibility of impact on the healthcare industry alone being transformative, more reliable and sustainable healthcare practices.
Photos: lvcandy, Getty Images
Laurie Masiello is the co-founder and CEO of Predictive Monitor, a company that empowers organizations through predictive analytics and strategic vision. She is famous for her motto as “warning and predicting success” and she advocates integrity, quality and resilience. Laurie was formerly CEO and co-founder of Masy Bioservices, a biopharmaceutical company that excelled in her leadership and was certified ISO-9001 and ISO-17025. Her work earned her the title of “Excellent Business Woman” in Worcester Business Magazine. Laurie is a dedicated community leader serving on multiple industry and nonprofit committees, where she shares her expertise and passion for innovation.
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