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. 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 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 and that exist 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 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 the fails. The technology behind this advance is called “prescriptive analysis” and was created to hypothesize the possible outcomes that could cause equipment downtime.
What's 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? According to the Deloitte Analytics Institute, predictive maintenance can reduce maintenance costs by up to 25% and, at the same time, increase uptime by 10 to 20%. Maintenance crews would only repair a machine when it broke down or became too dangerous to operate, involving costly repairs and a time of excessive inactivity. 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 optimized 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 track 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 usage-based maintenance and time-based maintenance (i.e., calendar-based maintenance). Most manufacturers use a combination of both in their facility's different assets.
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 maintaining machines based on how much they are used, rather than relying on a set schedule. Maintenance is carried out by monitoring metrics such as the hours used or the 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 detecting 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, which optimizes performance and prolongs the lifespan.
Leveraging preventive maintenance software represents a turning point. It's not just about keeping track of what needs to be done, but about planning, programming and executing strategies. These systems help ensure that maintenance tasks are performed on time and help analyze trends to make better decisions. 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 control panels 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 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.
Keeping an up-to-date inventory ensures that critical replacement 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 negligence, causing unnecessary downtime and resource expenditure. By tracking faults and analyzing data, you can adjust your maintenance schedule 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, plus seamless interoperability with major types of manufacturing software (e.g., MES, ERP, inventory management), programming panels, and mobile-compatible interfaces. 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. Preventive maintenance is a method of keeping all your assets in good working order to avoid equipment failures and unplanned downtime. It involves proactively scheduling maintenance tasks, such as inspecting equipment to detect potential problems before they become major problems for maintenance operations. Examples of preventive maintenance include cleaning and lubricating moving parts of equipment and replacing parts that wear out before they wear out. Regular maintenance helps extend the lifespan of your assets and reduce costs associated with unplanned maintenance and equipment repair and replacement.
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.
Time-based preventive maintenance involves performing routine maintenance tasks at predetermined intervals. 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. The maintenance team must then complete the repair as soon as possible to avoid further downtime. This type of maintenance is based on algorithms, machine learning, and artificial intelligence analysis to identify patterns and anomalies in the data that could indicate a maintenance problem. Preventive property maintenance is the important task of managing periodic inspections and repairs while the property's equipment continues to function properly.
Preventive maintenance uses historical data to schedule routine inspections, while predictive maintenance uses real-time data to monitor the condition of an asset and detect and resolve problems before preventive maintenance. A computerized maintenance management system, or CMMS, is a comprehensive preventive maintenance software that keeps track of your assets, automates work orders, and produces reports that help you make informed decisions in data on carrying out periodic maintenance. By coordinating preventive maintenance tasks with production schedules, you can minimize interruptions and maximize your maintenance resources. 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.
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. Proper planning with a checklist for building maintenance is crucial to implementing an effective preventive maintenance strategy. Reactive maintenance costs much more in the long term than a solid and comprehensive preventive maintenance strategy. It optimizes maintenance activities and reduces unnecessary maintenance tasks by using real-time data, historical records, and predictive maintenance models to determine the best preventive maintenance program for a particular piece of equipment.
Choosing the most appropriate preventive maintenance program for your facility requires careful consideration of several factors, such as the nature of your industry, the type of equipment and systems you use, and the resources available for your maintenance teams. A comprehensive preventive maintenance program helps extend the life of your equipment, keeps your assets working properly and efficiently, and can ensure that all essential preventive maintenance tasks are performed in a timely manner. Maintaining complete and accurate documentation of all preventive maintenance activities helps you track the cost and benefits of preventive maintenance for each piece of equipment, identify recurring problems, and ensure compliance with warranty requirements.
