Facility managers are likely to have heard the expression, “If it isn’t broken, don’t repair it.” It may be a good mentality in the short term, but constant reactive maintenance can cost thousands each year. Facilities teams can be stressful and take a lot of time to repair unplanned asset failures.
Is your team still using a reactive maintenance approach? It’s time to make a change. For equipment to be in safe and operable condition, a solid preventive maintenance program is essential. This guide to preventive maintenance is your one-stop resource for understanding and implementing your program.
What Is Preventive Maintenance?
Preventive maintenance is the proactive maintenance of assets to maintain their optimal condition. It reduces the chance of unexpected repairs or safety concerns. It prevents production from being halted, delays projects, and damages the company’s reputation.
- Documented maintenance requirements for individual assets.
- Maintenance tasks must be completed before the asset’s performance is compromised.
- Cues for teams to start the preventive maintenance work.
- Methods to track the progress of preventive maintenance tasks from their inception through their completion.
- A list of all parts and materials that were used in each preventive maintenance task.
- Documentation of what was done and when it was done by whom.
Action Items for Preventive Maintenance
Preventive maintenance is a proactive approach to maintenance. It involves four essential actions: inspection, detection, and correction, as well as prevention. Let’s examine how each concept is essential to a successful preventive program.
Inspections are essential for preventive maintenance and aid groups in two ways. First, equipment safety is ensured by facility inspections. Regular inspections can prevent injuries at work and increase liability protection. Second, regular inspections protect property. Regular inspections are necessary to ensure equipment works as it was intended.
A run-to-failure strategy can lead to significant financial losses for a facility department. This is why many facility managers opt to use a preventive approach in maintenance. Facility managers can detect potential problems early and fix them quickly.
Facility managers should encourage preventive maintenance and take proactive steps to ensure equipment is maintained. Facility managers should immediately address any potential issues or problems that are discovered.
Facility managers can use inspection records and maintenance notes to identify past errors and fix repeated problems with equipment. Preventing asset failures reduces stress and improves productivity for facilities staff. Staff can concentrate on proactive maintenance tasks when equipment is in good condition.
Benefits of Preventive Maintenance
- Improved asset life and reliability: Preventive maintenance is a proactive approach to asset maintenance that can improve asset reliability and asset life.
- Safety: This can reduce the chance of injury by ensuring that assets are maintained before they fail. A PM can also help you keep track of compliance and training.
- Equipment failures are less costly and require less downtime. These costs can be drastically reduced if preventive maintenance is done.
- Employee errors are less familiar with more detailed work orders and centralized, comprehensive documentation. This will reduce the chances of employees making mistakes on the job.
- Simple compliance: Automated PM automation, triggers, and documentation can simplify compliance.
- Sustainable operations: Assets that are well maintained use less energy over the course of time. Optimizing asset maintenance can help you to have lower energy bills and more sustainable operations.
- Increased employee productivity. High levels of downtime and disconnected information can hurt productivity and production. These concerns can be addressed by a PM.
- You can get repairs done faster by using PM. This allows teams to make sure maintenance occurs during planned downtime. This can reduce the time and cost of maintenance by ensuring that all parts, personnel, and supplies are available.
How to Create a Preventive Maintenance Program?
Nobody wants to cut corners or delay upkeep so much that asset failure is possible. It is important to remember that excessive frequency in preventive maintenance can lead to excess costs due to the lost work hours and replacement parts.
Preventive maintenance plans must be balanced and take into consideration many variables. Data should be used whenever possible to quantify the plan.
It is necessary that all departments in your organization evaluate and prioritize their needs before developing a preventive maintenance program. Leadership must be involved to see the whole picture of the business, including the financial implications of preventive maintenance plans. Engineers and operations teams need to consider the impact preventive maintenance will have on an enterprise. Maintenance teams also need to take into account historical asset performance, budgets, and workforce.
Asset managers should have data to support decision-making, helping multidisciplinary teams evaluate costs and benefits in detail. Your plan should start with maximum uptime. This can then be broken down into smaller and more specific maintenance schedules per asset type.
You’ll find some tasks that you can do on specific days. However, most of your maintenance schedules will be more flexible based on how the asset is used. You might, for example, set a goal to remove debris from the injection moulding machine at each production cycle or change the oil after a certain amount of miles.