Predictive replacement for heavy machinery

A method for predicting replacement of a component included in an industrial machine, the method comprising:

• receiving, with an electronic processor, data collected by a wear detection device representing a current dimension of the component;
• comparing, with the electronic processor, the current dimension of the component to discard criteria, the discard criteria including a discard dimension of the component;
• in response to the current dimension of the component being less than the discard dimension of the component, discarding the component;
• and
• in response to the current dimension of the component being greater than the discard dimension of the component,
• determining, with the electronic processor, a virtual measurement for the component at a future time,
• comparing, with the electronic processor, the virtual measurement for the component to the discard dimension, and
• in response to the virtual measurement for the component being less than the discard dimension, adding, with the electronic processor, the component to used pool of components.

Non-transitory, computer-readable medium storing instructions that, when executed by an electronic processor, perform a set of functions, the set of functions comprising:

• determining a replacement cost for a component of an industrial machine for each of a plurality of arrangements, wherein determining the replacement cost includes determining a cost of downtime for replacing the component based on a time for replacing the component and a downtime cost for the industrial machine during the time for replacing the component, a material cost in replacing the component, and an operating cost of the industrial machine associated with not replacing the component;
• determining a replacement recommendation for the component based on the replacement cost associated with each of the plurality of arrangements;
• and
• outputting the replacement recommendation.