The 4 Types of Preventive Maintenance · 1.Periodic maintenance, or time-based maintenance, is performed on assets at scheduled time intervals throughout the calendar year. While it can be done annually, quarterly, monthly, or weekly, the best way to know how often to do it is to follow a combination of the manufacturer's guidelines and your own observations. Each piece of equipment comes with specific maintenance recommendations designed to extend lifespan. These guidelines are based on the manufacturer's average time between failures (MTBF), or the average time a machine is working between stops.
If similar models operated efficiently for X amount of time before maintenance task A was needed, we can conclude that your machine will follow a similar pattern. That said, by keeping track of your own average time between hours, you can adjust your own periodic maintenance schedules with even greater levels of accuracy. It's also important to note that while regular maintenance works great for equipment that's used regularly, it's not effective on machines that are only used once in a while. In addition, periodic maintenance may include the subcategories of fault-detection maintenance (FFM) and risk-based maintenance (RBM).FTM is the process of checking for “hidden parts” that malfunction as security mechanisms.
According to IBM's Using the IoT for Preventive Maintenance report, 30 percent of preventive maintenance procedures are performed too frequently. However, numerous studies show that companies waste even more money by not practicing any type of proactive maintenance and simply reacting to unexpected equipment failures. Like predictive maintenance, prescriptive maintenance (RxM) makes decisions based on of the data. However, this cutting-edge method of monitoring equipment takes efficiency even further with machine learning software.
The intelligent software analyzes the monitoring of the condition of equipment over time, assesses operational risks and makes specialized recommendations that exceed the manufacturer's generic guidelines. While predictive maintenance can provide an estimated duration until failure, RxM allows maintenance teams to keep track of varying operating conditions up to the time of failure. The technology behind this advance is called “prescriptive analysis” and was created to formulate hypotheses about the possible outcomes that could cause stoppages in teams. The most interesting part of prescriptive maintenance? What's the difference between predictive and condition-based maintenance? What's the difference between preventive and predictive maintenance? Time-based or calendar-based maintenance is performed at scheduled time intervals, often in accordance with the manufacturer's recommendations.
For example, a maintenance technician can perform weekly maintenance on critical equipment to ensure maximum production levels and increase uptime. Prescriptive maintenance is a more proactive maintenance strategy than even predictive maintenance. When predictive maintenance identifies potential failures, prescriptive maintenance also provides specific corrective maintenance actions to prevent them from occurring in the first place. Risk-based maintenance combines elements of predictive and condition-based maintenance.
Evaluate the critical nature of an asset and the potential consequences of its failure. Assets with higher risk factors receive more frequent supervision and maintenance, while lower risk assets undergo inspections with less Frequency. Results-based management ensures that resources are allocated efficiently to protect the most crucial aspects of a facility's operations. Maintenance crews would only repair a machine when it broke down or became too dangerous to operate, involving costly repairs and excessive downtime.
This scenario is what preventive maintenance (PM) is intended to, well, prevent. Based on proactive measures to mitigate breakdowns, preventive maintenance systems are much more common today, although most facilities have not fully rationalized their preventive maintenance. In practice, preventive maintenance involves a systematic schedule that includes tasks such as lubrication, adjustments, cleaning and replacement of parts based on a predetermined schedule or usage metrics. It requires careful planning and extensive documentation to keep track of maintenance history and plan for future work.
When properly implemented, preventive maintenance leads to a significant reduction in unplanned downtime, large cost savings, greater production efficiency, fewer production delays, and a safer work environment. The two main types of preventive maintenance are use-based maintenance and time-based maintenance (i.e., maintenance based on calendar). Most manufacturers use a combination of both on different assets in their facilities. The type of preventive maintenance used depends on the requirements of each type of asset and the conditions under which it operates.
Usage-based maintenance focuses on servicing machines based on how much they are used, rather than relying on a set schedule. Maintenance is carried out by tracking metrics such as hours used or products manufactured. This method prevents excessive wear and tear, reduces costs, and keeps production running efficiently. Time-based maintenance schedules maintenance activities at specific intervals on a daily, weekly, monthly or annual basis.
The exact range depends on the type of equipment in question, its frequency of use and its operating conditions. Implementing a preventive maintenance strategy is undoubtedly the most effective way to reduce the costs associated with maintenance and downtime. By proactively finding and addressing equipment problems, companies can save hundreds of thousands of dollars a year. Like any large scale process implementation, this type of maintenance requires some planning, time, and incremental execution. A generic plan isn't enough.
Your preventive maintenance plan should be as unique as your operation. Develop customized schedules, procedures and checklists for each prioritized asset, incorporating both the manufacturer's recommendations and your own operational knowledge. This personalized approach ensures that maintenance activities are perfectly aligned with the specific needs of each equipment, optimizing performance and extending lifespan. Leveraging preventive maintenance software represents a turning point. It's not just about keeping track of what needs to be done; it's about planning, programming and executing strategies.
These systems help ensure that maintenance tasks are performed on time and help analyze trends for better decision-making. The ability to plan, schedule, execute and track maintenance activities through a centralized system will keep your operations running smoothly and efficiently. Consistency is key to preventive maintenance. By developing and implementing standardized maintenance procedures, you ensure that every task is carried out thoroughly and efficiently, regardless of who is performing it. This standardization not only improves the quality and reliability of maintenance work, but it also improves safety in all your facilities.
Your preventive maintenance strategy is only as good as the team that executes it. Make sure that your maintenance personnel are not only properly trained for the task you assign them, but are also equipped with the right tools and parts. Connected personnel platforms, such as L2L, ensure that maintenance tasks are completed on time and correctly by streamlining communication. For example, machine dashboards centralize machine and equipment data so that maintenance technicians have quick access to information, necessary tools, and operator notes.
Finding the perfect time for maintenance can be a challenge, but it's essential to minimize the impact on production. Plan your maintenance activities during periods of low production when possible, ensuring that your technicians have what they need to complete their work efficiently. Maintaining an up-to-date inventory ensures that critical spare parts are always available when needed, reducing the average repair time (MTTR) and streamlining the maintenance process. Don't waste all your planning because the technicians didn't have the right parts to perform the scheduled maintenance tasks.
It is important to monitor the performance of the equipment and adjust the frequency of preventive maintenance accordingly. Excessive maintenance can be just as damaging as carelessness, leading to unnecessary downtime and a waste of resources. By tracking failures and analyzing data, you can adjust your maintenance program to achieve the perfect balance between maintenance and productivity. Preventive maintenance is much easier to execute with the right software support.
You need a solution that provides a complete, real-time view of asset data, that automatically alerts technicians to mechanical problems, that helps you to easily schedule maintenance work, and that allows workers to easily share information in the shop. The L2L connected workforce platform offers manufacturers all of these benefits, in addition to seamless interoperability with major types of manufacturing software (e.g., MES, ERP, inventory management), programming panels, and interfaces compatible with mobile devices. L2L allows first-line teams to manufacture better together. Our Connected Workforce platform unifies collaboration, maintenance and OEE to make decisions based on data, gain real-time visibility and optimize operations. Drive actions that matter with clear information and a high-performing workforce.
A computerized maintenance management system, or CMMS, is comprehensive preventive maintenance software that tracks your assets, automates work orders, and produces reports that help you make informed decisions in data on carrying out periodic maintenance. This demonstration shows preventive maintenance scheduling, asset performance monitoring, and proactive maintenance workflows that reduce downtime and extend equipment life. Preventive maintenance is a maintenance strategy that is based on regular and scheduled maintenance activities to prevent equipment failures and unexpected downtime. A good preventive maintenance plan is based on factors such as the number and types of equipment you have, the importance of different types of assets, and the size of your maintenance team.
Advanced digital maintenance solutions facilitate and expedite the implementation and management of the preventive maintenance program. Creating the right program for your facility depends on understanding what the preventive maintenance process involves, the different types of preventive maintenance, and what should be considered when implementing an effective preventive maintenance strategy. Analyze the data, ask for the opinion of your maintenance teams, and keep up to date on industry best practices to continuously improve your preventive maintenance workflow and optimize the effectiveness of your preventive maintenance program. By monitoring key performance indicators (KPIs), such as equipment downtime during unplanned maintenance, the average time between equipment failures, and maintenance costs, you can identify areas where your preventive maintenance strategies can be improved and optimized.
It's important to regularly review and improve your preventive maintenance plan to get the most out of your proactive maintenance strategy. Reactive maintenance costs much more in the long term than a solid and comprehensive preventive maintenance strategy. A preventive maintenance checklist for electrical systems can include routine maintenance tasks, such as inspecting electrical panels and wiring, checking grounding and surge protection systems, and replacing damaged cables. Preventive maintenance processes also reduce the maintenance costs of emergency repairs (by preventing them from being carried out from the start) and provide information to better manage the costs of spare parts.
Regardless of the type of preventive maintenance program you implement, whether it's predictive maintenance or a time-based plan, it must include these essential elements. Reactive maintenance procedures can easily prove to be much more expensive than preventive maintenance, which attempts to anticipate equipment failures and take corrective maintenance measures before mechanical breakdowns occur.
