6 Types of Preventive Maintenance Strategies To Adopt For Your Business

Types of Preventive Maintenance Strategies

Preventive maintenance is a proactive strategy to maintain machinery, equipment, and systems and reduces the risk of unexpected breakdowns and extends operational longevity. It is a type of maintenance strategy that involves planned inspections, condition monitoring, repairs, and replacements before actual failure occurs, and has replaced corrective maintenance.

Proactive maintenance saves businesses from costs brought by an unplanned maintenance approach, as they address failure modes effectively. However, the strategy for maintaining equipment isn’t universal. It requires careful consideration of various methods tailored to different operational needs.

The diversity in preventive maintenance approaches stems from the unique requirements of each industry. Whether it’s regularly scheduled inspections or more condition-specific interventions, the right plan hinges on understanding the nuances of each type. Each type of preventive maintenance deals with specific challenges. The methods are:

  1. Time-based maintenance
  2. Usage-based maintenance
  3. Condition-based maintenance
  4. Predictive maintenance
  5. Risk-based maintenance
  6. Calendar-based maintenance

Below, we’ll dive deep into these six key types of preventive maintenance with examples. Each of them comes with its own distinct approach to handling equipment care. Let’s understand them better.

1. Time-Based Maintenance (TBM)

Time-based Maintenance (TBM) involves scheduling maintenance tasks at fixed intervals, regardless of the equipment’s actual condition. For example, factories producing automotive parts frequently use TBM for machines that require regular oil changes and filter replacements to maintain operational efficiency. These tasks are planned based on data provided by the manufacturer or historical usage patterns, allowing operations to keep moving without the fear of sudden breakdowns.

By sticking to a consistent schedule, businesses minimize the chance of unplanned downtime, which can lead to costly delays. Consider a food processing plant—here, machinery downtime doesn’t just halt production but also risks product spoilage. Time-based maintenance helps avoid such scenarios, leading to reduced waste and steady output.

Another compelling advantage of TBM lies in its predictability. A manufacturing firm producing electronic components, for instance, schedules routine inspections and part replacements to match production cycles. This proactive strategy prevents equipment wear from impacting the quality of the final product. While this method might seem like an upfront investment in time and labor, it saves hefty repair costs over the long haul.

2. Usage-Based Maintenance (UBM)

Usage-based Maintenance (UBM) takes a slightly more dynamic approach than TBM. Instead of relying on fixed calendar intervals, it measures the operation time or usage of equipment to determine when maintenance tasks should be performed.

For industries that rely on heavy machinery or systems with variable workloads, UBM can make a significant difference. Take production equipment or HVAC systems, for instance. The amount of time they’re actually in use fluctuates depending on demand, and with UBM, companies avoid unnecessary downtime or overuse. Let’s say an HVAC system is barely needed in the off-season but runs non-stop during the summer. Instead of servicing it too often, UBM ensures that the service only happens when it’s truly required, cutting down on maintenance costs and downtime.

When companies adopt UBM, they often see cost savings in maintenance. By preventing unnecessary checks, businesses can allocate resources more efficiently, focusing on actual wear-and-tear rather than calendar-driven maintenance schedules. For example, manufacturing plants that experience fluctuations in production demand won’t waste time or money on regular maintenance during slower periods. Plus, over time, the system is more likely to catch real issues before they lead to costly breakdowns or repairs, offering a good balance between cost and machine longevity.

3. Condition-Based Maintenance (CBM)

Condition-based Maintenance (CBM) represents a significant leap toward smarter maintenance practices. Instead of sticking to predetermined schedules, CBM leverages real-time data from sensors, gauges, and meters that continuously monitor the health of equipment. Once a condition outside the optimal range is detected, maintenance is triggered.

CBM saves money and time by aligning maintenance activities with actual equipment needs. For instance, a manufacturing facility using CBM to monitor its production line machinery avoids unnecessary servicing costs, which might otherwise add up to thousands of dollars annually. At the same time, catching potential failures early prevents catastrophic breakdowns that could disrupt operations for days.

The aviation industry has embraced CBM to monitor critical components like engines and landing gear. Using advanced sensors, airlines track performance data to anticipate wear, reducing the likelihood of in-flight issues. In another example, power generation companies use CBM to oversee turbines and transformers. Detecting minor anomalies in vibration levels allows them to replace parts during routine downtime instead of experiencing outages that might leave entire regions without power.

4. Predictive Maintenance (PdM)

Predictive Maintenance (PdM) can be thought of as an evolution of CBM but with a twist. PdM not only monitors the current condition of assets and equipment but also uses historical data, machine learning algorithms, and advanced analytics to forecast when a component or system will likely fail. Rather than implementing a reactive maintenance strategy, it offers insights to maintenance professionals on the possibilities that can unfold in maintenance.

Industries operating with complex and expensive equipment, such as power plants or aviation, adopt PdM due to its potential for minimizing downtime and avoiding unnecessary maintenance costs. However, setting up a predictive maintenance program requires an advanced Computerized Maintenance Management System (CMMS) integrated with sensors and AI-powered analytics, representing a more sophisticated and often resource-heavy investment.

Shifting to PdM requires an upfront investment in sensors, data infrastructure, and skilled personnel. However, the long-term payback far outweighs the costs. Companies see extended asset lifespans, reduced spare parts inventory, and optimized workforce allocation. A single predictive maintenance solution can result in up to a 20% decrease in overall maintenance expenses and a 25% increase in asset availability, according to industry reports.

5. Risk-Based Maintenance (RBM)

Risk-based Maintenance (RBM) is a specialized form of preventive care that focuses on identifying and prioritizing the risks associated with asset failures. Rather than treating all equipment equally, RBM ranks the importance of assets based on the likelihood and consequence of failure, concentrating maintenance resources on the most critical systems.

RBM has special importance in industries like oil and gas. Here, equipment like pressure relief valves rarely engage during normal operations. However, if a valve fails during an emergency, the consequences could involve massive operational downtime, regulatory fines, or even severe safety hazards. Implementing RBM with CMMS in oil and gas ensures these components undergo regular inspection and testing. As a result, businesses avoid unplanned outages, which, according to industry reports, save anywhere from $1 million to $5 million per day in lost production.

RBM is especially beneficial in industries where safety and compliance are non-negotiable. By focusing maintenance efforts on high-risk components, businesses can reduce both operational and safety risks. While RBM excels in safety-critical environments, it does require thorough risk assessments and constant re-evaluation as equipment and operations evolve.

6. Calendar-Based Maintenance

Calendar-based Maintenance is one of the most traditional and widely used methods. As its name suggests, preventive maintenance tasks are scheduled on a calendar, typically based on manufacturer guidelines or operational knowledge of the machinery. It could occur annually, quarterly, monthly, or even weekly, depending on the equipment’s design and maintenance needs.

CBM is employed by manufacturing businesses to maintain its equipment like conveyor belts. Regular maintenance, like lubricating parts every two months or replacing components yearly, helps reduce unexpected downtimes. For instance, the cost of replacing a conveyor belt prematurely due to neglect could reach $10,000 or more. On the other hand, planned maintenance at a fixed cost of $500 per session brings predictability to budgeting and avoids halts in production, which can be far more expensive.

Hospitals rely heavily on CBM for maintaining their medical equipment. Defibrillators, for example, undergo quarterly battery checks and annual calibrations to comply with regulations and maintain readiness. In agriculture, farm equipment such as tractors benefits from calendar-based maintenance. Farmers schedule engine oil changes and tire inspections ahead of planting or harvesting seasons.

Comparision Table

Maintenance Type

Advantages

Limitations

Best-Use Scenarios

Time-Based Maintenance

  • Simple and easy to implement.
  • Can be scheduled regularly for routine tasks.
  • Works well for equipment with predictable wear over time.
  • May lead to unnecessary maintenance or replacement before failure occurs.
  • Does not consider actual condition or usage.
  • Suitable for equipment with fixed lifespans or predictable wear patterns, such as elevators, HVAC systems, and industrial machines.

Usage-Based Maintenance

  • Maintenance is performed based on actual usage, making it more efficient.
  • Helps reduce unnecessary maintenance and downtime.
  • Requires accurate tracking of usage data.
  • May not account for unpredictable events or external factors.
  • Ideal for vehicles, machinery, or equipment that operates based on hours of usage or distance traveled, like forklifts, trucks, and generators.

Condition-Based Maintenance

  • Maintenance is triggered by real-time data, allowing for more precise intervention.
  • Can extend asset life by addressing issues as they arise.
  • Requires sensors and monitoring systems, increasing initial costs.
  • May not be effective if sensors fail or provide inaccurate readings.
  • Best for critical systems where downtime is costly or dangerous, such as aircraft engines, power plants, and high-value manufacturing equipment.

Predictive Maintenance

  • Uses data analytics and advanced sensors to predict failures before they occur.
  • Minimizes unplanned downtime and costly repairs.
  • Maximizes asset lifespan and operational efficiency.
  • High upfront investment in technology and training.
  • Requires reliable data collection and analysis systems.
  • Ideal for industries with complex machinery, like oil & gas, manufacturing, and utilities, where unexpected failures can lead to significant losses.

Risk-Based Maintenance

  • Prioritizes critical assets based on failure risk, optimizing resources.
  • Focuses on asset reliability and safety.
  • Complex to implement, requiring detailed risk assessments.
  • Might not be cost-effective for smaller operations.
  • Works well in industries with high safety or operational risks, such as chemical plants, aerospace, or nuclear facilities.

Calendar-Based Maintenance

  • Easy to plan and execute based on fixed schedules.
  • Ensures routine inspections and tasks are performed regularly.
  • Can result in unnecessary maintenance or downtime if not aligned with asset conditions.
  • Doesn’t account for actual usage or wear patterns.
  • Suitable for routine, low-risk equipment where time-based checks are sufficient, such as office equipment, lighting systems, or non-critical infrastructure.

How to Choose the Right Preventive Maintenance Strategy for Your Maintenance Needs

Preventive Maintenance Strategy

Choosing a preventive maintenance strategy calls for a thoughtful approach, balancing the unique demands of your facility with available resources and long-term operational goals. Follow these steps which offer a comprehensive method for selecting a preventative maintenance strategy that suits both your equipment and operational needs while remaining sustainable and adaptable in the long run:

  • Prioritize Asset Significance: Begin by determining the importance of each piece of equipment in your operations. Some assets are more crucial than others, and their failure can cause severe disruptions. Understanding which systems require more attention will help set maintenance priorities.
  • Examine Equipment Lifespan: Consider the different stages of each asset’s life, from installation to its operational phase, and eventually decommissioning. Crafting a maintenance plan that aligns with these stages ensures that each phase receives the necessary attention.
  • Identify Technological Complexity: More sophisticated machinery may demand specialized maintenance techniques like predictive models or condition-based monitoring. It’s essential to assess whether your equipment needs higher technical expertise or routine maintenance practices.
  • Leverage Past Data: Analyzing historical maintenance records provides insights into recurring failures or issues that could have been prevented. The data guides the process of optimization of future maintenance schedules, and makes them more proactive and efficient.
  • Consult Specialists: Getting expert advice from industry professionals or manufacturers is invaluable. They bring in-depth knowledge and practical insights that can help you select the best preventive measures for your specific equipment and environment.
  • Review Available Resources: Make sure to align your maintenance plan with the financial and human resources available. The size of your team, the expertise of your personnel, and the budget will dictate how comprehensive or streamlined your preventive maintenance approach can be.
  • Embrace Flexibility and Refinement: The strategy you choose should be adaptable over time. Regular evaluations based on operational feedback and advancements in technology will help you adjust the plan to achieve ongoing efficiency and improvement.

How a Computerized Maintenance Management System (CMMS) helps Implement Different Types of Preventive Maintenance

Framing a preventive maintenance program within a CMMS begins by establishing a comprehensive asset inventory. Each piece of equipment is logged into the system, complete with relevant details such as model, serial number, manufacturer recommendations, and usage data. The database enables a structured approach where maintenance activities are scheduled according to specific triggers—either time-based, usage-based, or condition-based.

For instance, time-based PM tasks might trigger every six months, while usage-based maintenance could rely on machine output like hours of operation. The CMMS uses these parameters to automatically schedule tasks, notifying the maintenance team and providing instructions, materials required, and safety precautions for each procedure. This approach promotes methodical tracking and reduces the chances of equipment failure or downtime.

The next step in building a PM program centers on customizing maintenance processes and reporting within the CMMS to track and improve performance over time. By assigning maintenance teams specific tasks based on priority and workload, the system balances resources more efficiently. Reports generated by the system offer insights into areas like task completion times, recurring issues, and equipment that consistently demands more attention.

Over time, these insights can lead to better decision-making, like adjusting maintenance schedules or reallocating resources to prevent equipment failures. Additionally, the CMMS provides historical maintenance data that helps refine the PM program by identifying trends that may suggest certain equipment needs more frequent attention.

Conclusion

FieldCircle’s preventive maintenance software streamlines various maintenance strategies. Its state-of-the-art automation capabilities revolutionizes maintenance. It automates time-based and calendar-based tasks, ensuring timely inspections and reducing the risk of neglect. For usage-based maintenance, the software tracks usage metrics and triggers maintenance based on predefined thresholds, helping extend asset life.

For condition-based and predictive maintenance, FieldCircle provides real-time monitoring tools that alert teams to potential issues, enabling proactive action before failure occurs. In risk-based maintenance, the software evaluates risk levels to prioritize tasks, ensuring businesses allocate resources efficiently and mitigate the impact of critical failures.

If you are planning to implement a well-executed preventive maintenance plan that goes beyond merely maintaining equipment, implement FieldCircle preventive maintenance software, which is an investment in long-term operational stability and success.