What is preventive maintenance and its benefits?
Preventive maintenance (PM) is the regular and routine maintenance of equipment and assets in order to keep them operational and prevent any unplanned, costly breakdown from unexpected equipment failure.
In a similar definition, preventive maintenance is the process of performing regularly scheduled maintenance activities to help prevent unexpected breakdowns in the future. Simply put, it's about fixing things before they break.
How does preventive maintenance work?
Through machine learning, operational data analytics and predictive asset health control, engineers can improve maintenance and reduce reliability risks to factory or business operations. Programs designed to support preventive maintenance (sometimes called preventive maintenance) help produce stable operations, ensure compliance with safeguards and solve problems affecting production - before they occur.
A successful maintenance strategy requires planning and scheduling equipment maintenance before a problem occurs. A good preventive maintenance plan also includes keeping records of past inspections and equipment service.
Due to the complexity of maintaining the preventive maintenance schedule for a large amount of equipment, many companies use preventive maintenance programs to organize the required preventive maintenance tasks.
What are the types of preventive maintenance?
There are 3 main types of preventive maintenance. Each is built around the concept of planned maintenance, although it is organized and scheduled differently, to suit the purposes of different business operations.
Mandatory tasks are those that must be performed as soon as they are due and will often include critical safety checks. Non-mandatory tasks are still important, but can be delayed without resulting in severe failure or decreased performance. Preventive maintenance checklist should divide tasks into mandatory or non-mandatory.
Hierarchical tasks occur when maintenance is set for a maturity date but is not completed and overlaps with later scheduled maintenance. In this case, if the new preventive maintenance mission is due, the previous one is cancelled. Cancellation must include a note to explain this and the new task must include the original due date to monitor the mission's delay. Some companies prefer a non-hierarchical structure, eliminating the need to notice the original task lost and taking the new date as a baseline.
Inspection and targeted tasks
Survey assignments require checks before converting results into work orders for planned maintenance to fix any problems discovered. Task-oriented task management allows for minor repairs and adjustments at the time of examination, reducing the amount of work to be written as working orders in the survey paper.
When is preventive maintenance required?
Precise requirements for preventive maintenance will vary depending on the equipment and process you perform. Industry uses standards to help determine maintenance schedules so that assets do not work with failure. This guidance will also cover the type of inspection or maintenance required.
Ideally, following guidelines set by manufacturers or standards, the preventive maintenance schedule should ensure proactive maintenance rather than having to resort to interactive maintenance when something has already begun to fail.
Following this type of predictive maintenance schedule, through tasks such as case monitoring, requires accurate recording of inspections and service versus understanding the life span of a particular piece of equipment. These records will help determine when preventive maintenance is required.
Examples of preventive maintenance
Industrial situations rely heavily on regularly scheduled maintenance to remain fully productive and free of costly and time-consuming mechanical breakdowns.
The term "preventive maintenance" covers a wide range of prohibited public activities and tasks. Each production component within the system will require a certain level of regular service, and this equipment will usually need cleaning and lubrication at least. In other cases, a more comprehensive service may be required - including heavy refurbishment, repair or even replacement of certain parts.
At a higher level, preventive maintenance also involves the provision of maintenance for the physical factory which includes various production systems. General tasks associated with this type of preventive maintenance include ensuring that the heating, ventilation and air conditioning system is in good working condition, that all electrical systems operate and comply with code standards, and all the necessary lighting works properly.
Benefits of preventive maintenance
Start getting maximum benefit from your assets and make cost savings by following a preventive maintenance strategy. Added advantages: larger organization and permanent operations.
Reduce the risk of breakdowns
Reducing crash risk is another key feature of preventive maintenance. In fact, most of the benefits mentioned here occur primarily as a result of lower risk of collapse. Waiting for maintenance to fail puts your facility at risk of losing productivity and damaged reputation.
Only about 10% or less of industrial equipment is truly worn out of proper use - this means that 90% of mechanical failures are caused by preventable problems, and can be avoided with a good preventive maintenance plan. By proactively scheduling maintenance, you can reduce the risk of equipment failure significantly, giving you peace of mind as a leader of installations.
Prolonged asset life
Arguably, the most important benefit of preventive maintenance is to prolong the asset's shelf life. Keeping your equipment in good condition allows it to work longer, reducing costs. MTBF - the average time between failures - is a common key performance indicator used by facility leaders to make informed maintenance decisions. Information tracking such as MTBF allows you to plan preventive maintenance at the right moment, capturing equipment before a failure occurs.
The power of a good downtime tracking system is so influential that 78% of companies that track and implement preventive maintenance reports experience an increase in the life of their devices.
Together with equipment that lasts longer, equipment undergoing routine preventive maintenance works more efficiently. OEE, the effectiveness of comprehensive equipment, is a commonly used key performance indicator for maintenance management that measures efficiency. OEE classifies equipment into three categories: availability, performance and quality.
A piece of equipment such as the heating, ventilation and air conditioning unit sees improvement across the board as a result of preventive maintenance.
Reduce unplanned downtime
Whether you decide to rely on interactive or preventive maintenance, machine failure is inevitable when making maintenance. However, downtime can be greatly reduced by scheduling maintenance in advance using the preventive maintenance plan. In case of reactive maintenance repair, the machine's downtime may be extended by waiting times to know the specialist mechanics or the time of shipping the necessary parts.
When you perform preventive maintenance, you have the opportunity to schedule the procedure in time for you and your facility (for example, when passengers are out of the building or operations are over for the day), reducing disruptions in production and efficiency.