How much unplanned downtime can predictive maintenance actually prevent?
In DHMSCare customer cases, unplanned downtime fell by 50% to 65%, depending on the equipment and its starting condition. Alerts arrive while a fault is still developing, so emergency repairs turn into planned maintenance. DHMSCare alerts are accurate in 90%+ of cases, so your team can move repairs from after a failure to before it.
Where the reduction comes from
Most unplanned downtime on rotating equipment starts as a slow fault: a bearing wearing out, a coupling drifting out of line, a gear losing teeth. These faults show up in vibration before the machine stops.
When the warning comes early, the repair moves into a planned stop with parts and people ready. The downtime does not vanish, but it becomes shorter and scheduled.
What DHMSCare customers report
In DHMSCare customer cases, unplanned downtime fell by 50% to 65%, depending on the equipment and its starting condition. In a food and beverage case, unplanned downtime fell by 68%.
At a coal-fired power plant, DHMSCare warned of misalignment on a secondary air fan eight days before it became severe. The same plant later reported a 65% drop in unplanned shutdowns.
What limits the result
Monitoring cannot prevent a failure nobody acts on. The reduction depends on how fast your team plans the repair once an alert arrives.
It also depends on coverage. Machines without sensors still fail without warning, so plants extend monitoring line by line to the machines whose stop costs the most.
Faults that start suddenly, such as a broken part or an operating error, give less warning than wear does. Monitoring helps most with faults that develop over time.
Questions buyers also ask
How early does a warning arrive?
DHMSCare alerts you to developing faults days ahead of failure. The actual lead time depends on the fault type and how fast it progresses, so it is never promised as a fixed number.
Will false alarms cost us downtime instead?
DHMSCare alerts are accurate in 90%+ of cases. An alert goes up to critical only when a change keeps growing or a second sign confirms it.
Which machines give the biggest reduction?
Usually the critical machines with no spare, where one stop halts the line, such as main drive motors, process pumps, fans and compressors.