Maintenance in the factory can take place for various reasons – for example, when a defect occurs or when a machine stops working. However, maintenance can also be carried out before these problems arise: preventive maintenance is key. In this article, we explain what preventive maintenance is, why preventive maintenance is important, and what benefits it offers.
What is preventive maintenance?
Preventive maintenance is a proactive approach where equipment and systems are regularly serviced to avoid unexpected failures. This includes inspection, cleaning, testing, lubrication, and timely replacement of parts. The goal of preventive maintenance is to extend equipment lifespan, improve efficiency, and prevent costly downtime or repairs. Therefore, preventive maintenance is essential in sectors like manufacturing, transportation, and facility management to ensure reliability and safety. A key guideline is the 10% rule: maintenance should be performed within 10% of the scheduled interval. For example, if a task is planned every 100 days, it should be completed between day 90 and 110. This ensures maintenance consistency and early detection of potential issues, leading to reduced costs and more stable operations.
Why is preventive maintenance important?
Preventive maintenance is important because it helps avoid unexpected equipment failures, reduces downtime, and extends the lifespan of machinery. By performing regular checks and servicing, issues can be identified and resolved early, preventing costly repairs or replacements. It also improves safety by reducing the risk of accidents caused by malfunctioning equipment. In industries where reliability is critical, such as manufacturing or transportation, preventive maintenance ensures continuous operations and higher productivity. Additionally, it allows for better planning and budgeting, since maintenance tasks are scheduled rather than emergency-based. Overall, it leads to long-term cost savings and more efficient, reliable performance.
What types of preventive maintenance are there?
We can apply different forms of preventive maintenance. It’s important to clearly understand the differences between these types of maintenance so that the right tasks are assigned to the appropriate maintenance activities. We distinguish between:
- Mandatory and non-mandatory tasks
- Inspection and task oriented tasks
- Pyramiding and non-pyramiding tasks
Mandatory and non-mandatory tasks
Preventive maintenance can be divided into mandatory and non-mandatory tasks. Mandatory tasks are essential for safety, compliance, or critical operations. Skipping these could lead to equipment failure, legal consequences, or safety hazards. Examples include pressure vessel inspections or replacing worn-out safety components. Non-mandatory tasks, on the other hand, help improve performance or extend equipment life but are not critical to immediate operation. Skipping them might slightly reduce efficiency but won’t halt production. Think of cleaning filters or checking non-essential components.
Inspection and task oriented tasks
Moving on, preventive maintenance includes both inspection tasks and task-oriented tasks.
Inspection tasks involve visually or technically checking equipment to detect early signs of wear, damage, or failure. This could be monitoring vibration levels, checking for leaks, or measuring temperatures. Task-oriented tasks are more hands-on and involve actual interventions like lubricating parts, replacing filters, tightening bolts, or changing fluids. Often, inspection tasks lead to task-oriented actions when an issue is discovered.
Pyramiding and non-pyramiding tasks
In some preventive maintenance planning schedules, tasks are grouped based on timing and frequency. Pyramiding tasks means that less frequent, larger maintenance tasks include the smaller, more frequent tasks. For example, a 6-month service might include all tasks from the monthly, 3-month, and 6-month intervals. This reduces redundancy and improves efficiency. Non-pyramiding tasks are planned independently. Each task stands alone and is performed on its own schedule, regardless of whether other maintenance is being done at the same time.
What are the benefits of preventive maintenance software?
Preventive maintenance software offers several key benefits. It helps with creating preventive maintenance schedules and track maintenance tasks efficiently, reducing the risk of missed inspections or delays. By automating reminders and centralizing data, it improves organization and ensures consistency in maintenance activities. The software also enables better planning by providing insights into equipment performance, history, and costs. This leads to reduced downtime, fewer unexpected breakdowns, and extended asset lifespan. In addition, it supports compliance with safety and regulatory standards through accurate documentation.
What is the difference between preventive and routine maintenance?
The main difference between preventive maintenance and routine maintenance lies in their purpose and planning. Preventive maintenance is scheduled based on time, usage, or condition to prevent equipment failures before they occur. It includes tasks like replacing worn parts, lubricating machinery, or performing safety checks to avoid breakdowns and extend asset life. Routine maintenance, on the other hand, consists of regular, often simple tasks performed frequently – daily, weekly, or monthly- to keep equipment in good working condition. Examples include cleaning, checking fluid levels, or tightening bolts.
Both types are essential, but preventive maintenance is more focused on long-term reliability and performance, whereas routine maintenance ensures day-to-day functionality.
Questions about preventive maintenance? Contact us!
EZ Factory helps streamline preventive maintenance by offering easy-to-use digital checklists through its EZ-GO platform. These checklists ensure that maintenance tasks are performed consistently, on time, and according to standard procedures. Operators and technicians can access the preventive maintenance checklists you have made via tablets or smartphones, reducing paperwork and human error. Tasks are clearly documented with step-by-step instructions, photos, or videos, making execution simple and efficient. Curious about the benefits you can gain from implementing preventive maintenance? Be sure to get in touch with us!