How to choose the right maintenance strategy (with 4 questions) Maintenance strategies ensure that all required maintenance tasks are completed in a timely manner, reducing the risk of operational failure or downtime. Is there such a thing as the best maintenance strategy? If you are stuck in a reactive mode, it is very challenging to make a successful transition right to predictive maintenance. We are going to exclude total productive maintenance, autonomous maintenance, and corrective maintenance from this comparison as those are concepts that can be applied on top of any maintenance strategy you decide to run. When production halts, the plant supervisor will utilize available resources to coordinate a work order. According to our 2021 maintenance report, preventive maintenance is the most popular asset management strategy. As we mentioned, RCM may encompass all of the other strategies depending on the equipment component and the available resources. critical assets; highly automated systems with a lot of condition and performance data. Ready to discuss your operational goals and challenges? It involves regular inspection, monitoring, and proactive measures to minimize equipment downtime and extend its lifespan. Because of that, it is hard to jump two or three steps ahead. If you are purely reactive, dont have a CMMS, and your maintenance logs are a mess, your organization is probably not ready to run RCM. Occasionally review available maintenance data to see if your maintenance schedules can be improved and if everyone is following outlined procedures. What is Condition-Based Maintenance? A Guide to CBM Strategy [1] Figure 2 taken from slides from IMaintain Conference 22 March 2012 from Accenture Marc Hoppenbrouwers (Accenture) and Marc Couturier (SAS) titled Analytics opens a new dimension for maintenance (Breakfast Masterclass), [2] Figure 6 adapted from Ledet, W.J., Making the move toward a learning organisation a classic journey of change. Preventive maintenance is a cost-efficient maintenance strategy intended to reduce downtime and extend the lifespan of all machinery. A good maintenance strategy is one that achieves high uptime for key equipment at low maintenance costs. It can happen one of two ways: Preventative maintenance can be costly so it is most suited for facilities that require routine inspection. Lean Management and Operational Excellence, How is your organization doing? A maintenance strategy is a systematic approach to ensuring equipment reliability and optimal performance in an industrial setting. Required fields are marked *. by providing analytics on all potential failure modes and building a custom plan to address each parts stability. In terms of performance of the maintenance operation, the most fundamental measure of success is the availability of the equipment the operation is responsible for. If you already have the software implemented, the basic steps to create the maintenance calendar are: When all of that is done, you can open the maintenance calendar to overview the maintenance schedule. You change the oil in your cars engine (thats preventive maintenance) to keep it running so the engine doesnt seize and youre not late for work. Its really perfect, esp. This should especially include costs of both repair and downtime in case of failure. Guide to 9 Different Types of Maintenance Strategies | Fiix It's important to develop a mix of different strategies to properly maintain your assets and ensure that they remain in working . There are many variants of RBM. How much time do people use doing activities that dont add any value to the goal of achieving the best results? Preventative maintenance reduces the risk of breakdown by routinely monitoring the performance and condition of your assets. The best strategy is determined by the concerns that you want to address. In reality, predictive maintenance is a more evolved form of preventive maintenance. Preventive maintenance is critical to ensure long life and great gear performance. Instead of following a fixed schedule, maintenance managers can rely on condition monitoring data and the P-F intervals to schedule work based on the current condition of the asset. Much like annual or mileage-based service on consumer vehicles, preventative maintenance is often time- or. However, to be successful, it also involves consideration of the various non-technical inputs into the maintenance operations model such as involving all the players in the maintenance team in a deliberate way, managing the funding needed for the improvement effort, benchmarking maintenance performance with your peer operations, and managing the prevailing culture. various software and hardware solutions, condition monitoring sensors, predictive analytics, specialized training in data science and predictive modeling. The benefits of reactive maintenance are that there is no initial cost or complex planning. Where there is an absence of best practices, that would indicate a lower level of capability. The following blog post shares the four primary maintenance strategies in use today, along with their advantages and disadvantages. Ensure all assets you want to track are entered into the CMMS database. Maintenance departments are faced with all kinds of limitations like: Most (if not all) of these challenges stem from tight maintenance budgets. Take a free DPA self-assessment, How to get the most out of your companys lean leadership training, Changeover improvements help company boost machine output and reduce waste. Paul Adams, Maintenance Strategy Manager, GlaxoSmithKline. Copyright 2023 Limble CMMS. Predictive Maintenance (PdM) requires an investment either in analytical equipment and user training or contractors to do the analysis. The four main maintenance strategies are run-to-failure, preventive, condition-based, and predictive. When choosing a maintenance strategy, it is important to understand you budget, goals, and risk tolerance. They influence reliability at the design stage through selection of components, layout and configuration of equipment, and can be called on to work with customers to improve reliability issues. Condition Based Maintenance (CBM) - this is often used synonymously with predictive maintenance The distinction? It must be remembered that by the time equipment is in use, the inherent reliability of the equipment has been established. However, reactive maintenance is not a practical solution in the long term for repairable assets. These may vary among industry sectors and may need the external view of a specialist consultant to help define them. Maintenance Strategies: Which One Best Suits Your Business Needs often represents a lack of an actual maintenance strategy. That information is then used to create more efficient maintenance schedules. Technicians assigned to affected tasks will immediately get an email and push notification informing them about the change in priority. Public Housing Authority Sustain the Benefits of Recent Renovations. Maintenance strategy doesnt enter our non-technical brains unless it directly affects our productivity and well-being. Some general guidelines for choosing a maintenance strategy: Preventive Maintenance (PM): Youll need to develop detailed job plans that spell out the maintenance tasks and the time intervals for each to keep the equipment up and running. Industrial PdM can be used for all equipment, or it can be reserved for your most critical assets. Maintenance Strategies Compared. The maintenance strategy they choose can have significant financial consequences. It is important to be clear about what capabilities are required for the accomplishment of the maintenance objectives. It uses vibration analysis, ultrasonic testing, infrared testing, and other techniques to assess the current condition of an asset and its components. of failure is useful in answering how important it is to prevent failure from happening. How have you resolved the issue of which maintenance strategy to employ in one or more scenarios at your facility? The first step in developing a robust maintenance strategy is to understand how mature the operation currently is. Set up the department up to be effective and efficient, and keep the area clean and organized. Save my name, email, and website in this browser for the next time I comment. It is fairly easy to set up and doesnt require a lot of training. Facility maintenance software can monitor equipment performance and identify patterns to predict when a breakdown may occur. Maintenance Strategy is an approach which aims at maintaining the current market share of a product or brand, with continuous but limited investment in marketing, especially in low share or stagnant markets. Write CSS OR LESS and hit save. This site uses cookies to store information on your computer. Examples include oil analysis, vibration analysis, and thermal analysis. and send them PMs and work requests throughout the software. Sign up for a Demo or email us at sales@simplefm.com. Each of the five basic maintenance strategies preventive (aka planned), reactive, predictive, condition-based, and reliability based has its own distinguishing features and optimal applications. Prescriptive maintenance strategy represents the most advanced approach to asset maintenance. Although the reliability and safety requirements of the organisations assets should be at the core, a robust strategy also defines what capabilities the maintenance team needs, and aligns all the efforts of the equipment designers, users and maintainers towards a proactive maintenance culture. Ultimately, it helps you build the most effective maintenance schedule for the analyzed piece of equipment. SimpleFMs facility maintenance software and experienced team help organizations manage, monitor, and control maintenance including: equipment, resources, and regulatory compliance. In fact, there is no clear, universally agreed definition about what exactly constitutes a maintenance strategy across industry bodies, and the guidance about what makes a good one is quite hard to find. 1: Understanding current maturity The first step in developing a robust maintenance strategy is to understand how mature the operation currently is. The assessment begins with defining the main sub-functions within the operation that it needs to perform in order to provide maximum value to the organisation: planning and executing maintenance, managing spare parts and managing maintenance budgets will be general to all maintenance operations but others may be specific to an industry. the illustrations and statistics, Im an Asst.Prof. The downside is that data can be misinterpreted, and creating an Internet of Things in your facility can be expensive because it requires installing other equipment like sensors. It assists managers in managing equipment and other assets. A different approach is needed. What is Maintenance Planning? Definition, Types, Example - The Likewise, theyll be notified about any new work that was just assigned to them. The deferred maintenance backlog starts to grow and operational issues become unbearable. Plant Engineering recently gathered a lot of information about how maintenance professionals feel about these strategies. Industries need reliability programs to ensure profit in terms of better utilization of existing production resources. However, this can lead to excessive maintenance like replacing parts that could still be used for a while. A maintenance strategy is a system developed to keep your facilitys assets in the best shape, reduce expenses and downtime, and increase productivity. Reliability Centered Maintenance (RCM) is a great maintenance strategy and considered the most cost-effective overall. We know it is hard to juggle everything in your head at the same time. very high upfront costs with the highest potential ROI over time. Drive motor can overheat due to inoperational fan. Maintenance professionals who have hundreds of millions of dollars riding on consistent production and on-time delivery know there is much more to the story. Maintenance Management Program Fundamentals - FMX RCM is a complete engineering approach designed to do whatever it takes to promote the greatest level of equipment reliability with the least investment of maintenance cost. Service providers and building owners know that managing multiple work orders at once can be more of a headache than its worth. Give us a call or fill in the form below and we will contact you. Your email address will not be published. When selecting a maintenance strategy, we can confidently say that being proactive is better than being reactive. When choosing maintenance strategies, different factors must be considered. Backed by sensor information, this cost-saving strategy eliminates the guesswork inherent in reactive and preventative maintenance strategies. Types of Maintenance: The 4 Main Maintenance Strategies Though RTF maintenance is reactive, operational managers sometimes deliberately choose this maintenance plan. It must be noted that risk values are always subjective and prioritizations based on this approach are debatable. A common example is an electric motor rated at 5hp or less. For example, a facility that is likely to experience failure if vital industrial parts that are at high risk of water contamination exposure. Selecting the right approach to each assets maintenance regime is therefore fundamental. A good working relationship with the supplier of equipment is an important determinant of success in any reliability programme. Between back-and-forth emails, missed phone calls, and late-night text messages, its easy to drop the ball on one or several important maintenance tasks. Equipment users have an underrated role in the maintenance team. These state-of-the-art sensors are revolutionizing the way we approach NDT and predictive maintenance, offering a comprehensive and reliable solution for real-time monitoring. changing the filter every couple of months; changing the oil every three weeks, after X amount of working hours; every X production cycles. A robust maintenance strategy creates a focus for the maintenance operation and creates a consistent ambition for the maintenance team, aligned to the needs of the parent organisation. By devising and implementing a thorough, company-wide approach to asset management, you can eliminate inefficiencies and ensure that critical operations are performed consistently. If we looked at maintenance strategies in isolation, we could objectively say that prescriptive maintenance is the way to go. On key equipment, the goal should be to deliberately select the right maintenance approach for each type of equipment failure that minimises the overall cost of the failure to the organisation. Lets take a conveyor belt for example. They vary in the level of damage they can do, how quickly they can be addressed, how expensive they are, and what is their chance of occurring in the first place. The term maintenance maturity describes how well developed an operations maintenance processes and systems are, and to what degree they deliver value for the wider operation. Figure 6 shows the relationship between culture and maintenance maturity (developed by Ledet and others [2]). The RCM analysis is based on identifying potential functional failures, failure root causes, and the severity of their downstream effects (which is basically an FMEA analysis). This approach focuses on recognising the failures that compromise the system the most and adopt the best strategy for each critical asset. The most proactive approach should be selected for the asset to reduce long term costs by focusing primarily on the wider cost of equipment failure. When conducting maintenance tasks, there are a few things to keep in mind. 4 types of maintenance strategy, which one to chose? A sample of a maintenance calendar inside of a Limble CMMS. Evaluating consequences (economical, environmental, safety, etc.) The exact cost ratio differs from industry to industry but when the full cost of service interruptions, lost orders, loss of reputation or government fines or other losses are considered, prevention of failures is frequently more cost-effective than waiting for the failure to occur.