What Is Preventive Maintenance?
Preventive maintenance (PM) refers to scheduling routine maintenance of equipment to prevent unexpected downtime from machine failure and avoid unplanned expensive repair works. As the name suggests, preventive maintenance is done while the machine is still functional to prevent sudden failure.
Preventive maintenance is a type of proactive maintenance strategy. It involves inspecting, adjusting, and repairing production-critical equipment to ensure optimal performance and reliability. Planning an effective preventive maintenance strategy involves storing and analyzing complex maintenance data on a large number of machines. Several organizations use preventive management software integrated with the asset management module of an ERP system to facilitate and streamline maintenance data management.
Importance of Preventive Maintenance
- Preventive maintenance helps lay the foundation for successful maintenance management, ensuring equipment and assets run efficiently.
- An effective preventive maintenance strategy minimizes operational disruptions by keeping the machines performing.
- It prevents workplace accidents and improves safety for the workers.
- Organizations can eventually meet their short and long-term maintenance goals and quantifiable results through total preventive maintenance.
Preventive maintenance is a form of Enterprise Asset Management (EAM), which refers to effectively managing the lifecycle of physical assets.
Preventive Maintenance Types
Preventive maintenance is a combination of preventive and maintenance, meaning routine equipment maintenance to prevent unexpected operational downtime. It is performed on all equipment parts to prevent wear and tear damage. There are four primary preventive maintenance types:
1. Time-Based Maintenance
The time-based maintenance tasks follow a pre-defined calendar that schedules maintenance tasks at fixed intervals. For example, a company can set a trigger to undertake maintenance work on the first day of every month.
2. Usage-based Maintenance
As the name suggests, a usage-based maintenance alert gets triggered when a machine’s use hits the benchmark. It can include the number of units produced, hours run, or production lifecycle.
3. Condition-based Maintenance
In condition-based maintenance, the team schedules maintenance tasks after inspecting the maintenance requirements of the machine. It monitors specific parameters for indications of declining performance or failure. For instance, the team will schedule repair work when the vibration of the machine reaches a certain threshold.
4. Predictive Maintenance
Predictive maintenance is a maintenance strategy that uses sensors to monitor the machines in real time and data analytics to analyze the data to predict failures. Predictive maintenance uses machine learning to develop an algorithm that helps find patterns and trends in machine performance to generate accurate maintenance alerts.
Preventive maintenance is conducted irrespective of the machine’s condition. It follows a maintenance calendar based on the recommendations made by the asset manufacturer. Several companies use computerized maintenance management systems (CMMS) software to streamline and simplify maintenance activities.
How Does Preventive Maintenance Work?
Preventive maintenance is a relatively straightforward strategy to plan and monitor. Organizations avoid cost overruns by proactively planning maintenance tasks. They use CMM software to set triggers based on usage or time. The software triggers alarms when maintenance work is due.
CMM software offers a centralized platform for visualizing data maintenance data. It is a vital tool since it allows the maintenance team to set a calendar for every PM task. An integrated ERP application reduces manual intervention and ensures consistency in every step of the PM activities by eliminating the requirement for generating new tasks every time. Organizations benefit from long-term cost advantages and automation of scheduling PM tasks.
The CMM simplifies the process by internalizing preventive maintenance as a part of management. The team leveraging product lifecycle software performs regular inspections following the maintenance calendar.
When Is Preventive Maintenance Required?
The exact requirement of preventive maintenance will depend upon the criticality of the machine and the operation it is performing. Industry uses various parameters and standards to determine the need for maintenance work. Here is a checklist to help you determine the requirements of maintenance work.
Assets suitable for preventive maintenance
- Have failure mode that can be prevented or lowered by preventive maintenance
- Machines with higher chances of failure that increase with time
- Machines that are critical for operations and regular maintenance can improve lifespan, performance, and workplace safety
Assets unsuitable for preventive maintenance
- Machines that are not critical for operation
- Experiences random failure unrelated to maintenance
- Machines with significantly higher repair costs
How to Start a Preventive Maintenance Schedule
For any organization, the machines are the most critical assets and regular maintenance helps to improve machine efficiency. You can start a preventive maintenance schedule by following the steps below.
1. Identify the End Goal
Preventive maintenance can reduce downtime, enhance equipment efficiency, improve workplace safety, and lower repair expenses. Before scheduling a PM plan, it is crucial to define the overarching objective.
2. Evaluating Asset Criticality
Performance criticality assessment involves evaluating each piece of equipment scheduled for PM based on its criticality in continuing operation and potential consequences in case of failure. This step is crucial to prioritize the maintenance tasks and optimize resource allocation.
3. Establish Labor and Resource Requirements
Performing preventive maintenance tasks effectively demands the involvement of labor and resources. Planning at the early stage will ensure the availability of skilled professionals and resources to execute the activities.
4. Long-Term Scheduling
Develop a long-term maintenance plan outlining the tasks over an extended period. Long-term planning allows efficient scheduling of maintenance activities and prepares a budget.
5. Short-Term Scheduling
Establishing a short-term schedule detailing each specific work allows for more immediate planning and execution of maintenance works. It also helps with better planning of budget and allocation of resources to ensure tasks are completed on time.
6. Training and Communicating Goals
Clear communication is essential to establish short and long-term maintenance goals. For the success of a PM plan, the organization must arrange proper training for the employees on the objectives, procedures, and expectations associated with the preventive maintenance schedule.
How to Implement A Preventive Maintenance Program?
Introduction to preventive maintenance in your organization needs planning. One of the best ways is to start with a pilot program and determine its success rate. It should start by identifying a few machines based on their criticality in operation and repair costs.
You can use the data gathered from the pilot to plan an ideal preventive maintenance schedule. It can help to standardize the process and provide a real-life example to compare success metrics.
Preventive Maintenance Advantages
Here are the critical preventive maintenance advantages.
1. Reduced Downtime
By performing regular maintenance, the team can intervene to prevent critical damage before the situation escalates. Preventive maintenance is a proactive strategy that helps lower downtime issues arising from unexpected maintenance and lower maintenance costs.
2. Extended Equipment Lifespan
Regular maintenance helps prolong the lifespan of equipment by keeping the parts in good condition. Unlike reactive maintenance, proactive maintenance allows the team to readjust and realign machines while those are still functional.
3. Enhanced Efficiency
Well-maintained equipment operates more efficiently and consumes less energy and resources. It helps maintain the quality of the equipment, resulting in better output.
4. Improved Safety
Regular maintenance can help avoid safety hazards and prevent accidents. Well-maintained machines are less likely to malfunction and reduce the chances of workplace accidents and liability issues.
5. Better Asset Management
Preventive maintenance entails a detailed record keeping of all equipment, parts, and maintenance activities, offering clarity to the system. The software facilitates data collection from multiple sources and identifies trends for informed decision-making.
6. Compliance With Regulation
In many industries, regulation standards require organizations to follow regular equipment maintenance for workplace safety. Preventive maintenance allows organizations to stay compliant with regulatory requirements by streamlining the process.
Preventive Maintenance Disadvantages
While an organization can derive numerous benefits from preventive maintenance, it is also essential to understand the potential challenges they might face. We have listed the common preventive maintenance disadvantages.
1. Upfront Costs
Implementing preventive maintenance involves costs of resources, such as labor, equipment, training, etc. For small and mid-size companies operating on a tight budget, these initial costs may be a barrier to implementing PM.
2. Difficulties With Over-Maintenance
Sometimes performing maintenance activities too frequently can result in wasted resources. It may lead to unnecessary downtime, increased machine wear and tear, longer production schedules, and increased expenses.
3. Resource Allocation
Determining the correct frequency and scope of preventive maintenance can be challenging. Allocating resources to non-critical tasks would result in wastage and increased overheads.
4. Environmental Impact
Preventive maintenance works can impact the environment by increasing resource consumption, like water, energy, and chemicals. Excessive maintenance work can adversely affect the organization’s sustainability policies.
Differences Between Corrective Maintenance and Preventive Maintenance
| Aspect | Preventive Maintenance | Corrective Maintenance |
| Purpose | The target is to prevent unexpected breakdowns and downtimes | Perform repair works when the issue arises |
| Timing | Performed at regular intervals following a predetermined schedule (monthly, weekly, etc) | Adhoc and performed when the issue arises |
| Goal | Lower the events of machine failure, improve workplace safety, and prolong the lifespan of equipment | To repair and restore the equipment as quickly as possible |
| Approach | Proactive: Inspections, lubrication, adjustments, etc. | Reactive: Diagnosis, repair, and replacement |
| Cost | Offers better cost advantages in the long run due to fewer breakdowns and improved efficiency | Repair costs can be high because of emergency |
| Equipment Performance | Helps maintain consistent performance by keeping the machines in good condition | Corrective maintenance doesn’t impact the performance of the machine |
| Planning | Requires proactive planning and scheduling of resources and labor | Usually planned and requires immediate action. Performed when the machine breaks down |
| Risk Management | – Helps reduce workplace accidents – Reduces incidents of major failures |
Takes action only when the failure occurs |
| Equipment Longevity | Extends equipment lifespan through regular inspections and repair | May result in equipment failure if neglected |
| Workforce Efficiency | Planned activities lead to better allocation of resources and team | Requires immediate mobilization of resources |
| Documentation | Well-documented maintenance records using maintenance management system | Documents could be lacking or incomplete |
Preventive Maintenance Examples
Preventive maintenance is a strategy that helps an organization improve output quality, increase equipment uptime or overall equipment effectiveness, and reduce cost. An efficient maintenance strategy aligns with the organization’s goals and works towards them.
These are some examples of preventive maintenance.
Equipment Cleaning
Machine performance declines as dust and dirt build-up. It causes friction and eventually leads to a failure. During regular maintenance, the team cleans up contaminations and prevents premature wear.
Lubricating Machine
Checking and changing the lubricating oil is also a part of preventive maintenance tasks. Lubricating oil is vital for keeping the machine parts working. The maintenance team will ensure the machine is lubricated to prevent unexpected failure.
FAQ’s
1. What Is Preventive Maintenance Meaning?
Preventive maintenance definition refers to a proactive maintenance strategy that includes periodic inspection and repair of equipment and parts to prevent machine failure before the issue escalates.
2. What is Total Preventive Maintenance Definition?
Total Preventive Maintenance meaning is a proactive maintenance strategy aimed at maximizing equipment effectiveness and minimizing breakdowns. It involves routine inspections, cleaning, and servicing to prevent potential failures. TPM integrates maintenance into daily operations, fostering a culture of continuous improvement and increasing overall equipment reliability and efficiency.
3. How Does Preventive Maintenance Differ From Reactive Maintenance?
Total preventive maintenance is a proactive strategy that involves scheduling inspection, repair, readjustment, and replacement to prevent a failure before it occurs.
In contrast, corrective maintenance is a form of reactive strategy that responds to a failure when it occurs.
4. What Are the Advantages of Preventive Maintenance Program?
Preventive maintenance offers numerous benefits.
- Preventing unexpected machine failure downtime caused by machine failure
- Improve workplace safety
- Reduce costly repair costs
- Improve overall machine efficiency and extend lifespan
5. What Resources Are Needed to Establish a Preventive Maintenance Plan?
Establishing preventive maintenance plans requires maintenance management software, skilled maintenance teams, spare parts, tools, and proper documentation systems.
6. How Can You Measure the Effectiveness of Preventive Maintenance Program?
You can establish a few key performance indexes to track the success of a preventive maintenance plan.
- Uptime
- Mean time between failures
- Mean time to repair
- Compliance with the maintenance schedule
- Maintenance costs
- Overall equipment effectiveness