Choosing the Right Maintenance Strategy

What are the best ways to choose the best maintenance strategy for your business? From the outside, those looking at the inside may think that the idea of selecting a maintenance plan is as easy as choosing between repairing it’ and replacing it’; however that’s not completely incorrect. Beyond the surface, however, there are a variety of factors that can affect the long-term viability of the company’s bottom line as well as its ultimately its viability. Particularly, when dealing with a lot of expensive equipment that is susceptible to wear and tear, as well as the eventual failure that affects every machine, the cost of maintenance could take a huge chunk out of earnings.

There are many strategies for maintaining your home that has changed over time as technology has allowed us to employ new methods employing new models before unimaginable. Let’s take a look at some of the most well-known maintenance methods:

Reactive Maintenance

This is the most straightforward method, often referred to as breakdown maintenance. The idea behind it is simple to use an item until it is not be used anymore. Then, take the steps that need to be done to fix it and return it to work. If it’s not repairable, then replace it. There are a few advantages when compared with other strategies like less initial cost and less personnel, in addition to not having to plan. But these advantages are often diluted in the long run due to unplanned downtime, shorter lifespan of assets, and the inability to anticipate breakdowns and maintenance requirements. The only legitimate reason to implement this strategy is the inability to pay for the initial cost of any other method.

Preventative Maintenance

The preventative maintenance process is carried out when an asset remains operating to reduce the chance of failure. In this method, maintenance is conducted in accordance with a set date or time. For example, routine maintenance is scheduled when the machine had reached 5 000 hours of operational time from the time of when it last had maintenance. Predictive maintenance is typically able to keep the equipment running at higher efficiency and prolong the lifespan of the asset as compared to reactive maintenance. It is making sure that there is no unnecessary downtime. However, it does require more planning and resources. It is not the best option for equipment like circuit boards which are prone to fail at random, regardless of the maintenance. It’s also not a good option for equipment that does not have a crucial role and is not likely to cause interruption when there is a failure.

Predictive Maintenance

The goal for predictive maintenance is to anticipate an imminent failure and then perform maintenance before it happens. This approach requires some particular conditions monitoring. It will usually be more expensive upfront because of the necessity to purchase sensors or additional equipment, and it will require highly skilled workers who are able to anticipate failures by analyzing the data points that are being observed. The advantages include the ability to reduce any unnecessary downtime and the reduction of time required to perform maintenance since it only occurs in the event of imminent failure. Predictive maintenance is generally not the best option when assets do not fulfill a crucial purpose or are not in a predictable failure mechanism.

Condition-Based Maintenance

Condition-based maintenance is comparable to predictive maintenance because it is continuous monitoring of specific conditions to determine the time when maintenance should be conducted. The majority of the time, it is, however, that maintenance based on condition is not only done to avoid failure and to guarantee optimal efficiency. This can not only increase productivity but also extend the lifespan of the asset also. Since condition monitoring equipment and the associated expertise are costly initially, the initial cost can be costly in certain cases. In the long term, however, maintenance based on condition could be the most efficient method to ensure maximum efficiency and longer lifecycles for assets. Condition-based maintenance is typically not the best option for older or non-critical assets that might be challenging to upgrade with sensors.

When you are deciding on a maintenance strategy, Think about your objectives that are both short-term and long-term. Consider which of your assets are essential and which ones aren’t. Estimate the Cost for interruptions (per minute, hour, etc.). Be aware of any information that could already be available to you to track. Consider the costs and benefits of installing sensors to monitor vibration, temperature electrical currents, subsurface imperfections (ultrasonic sensing), or leaks in vacuum (acoustic sensor). Calculate the cost of maintaining personnel in various situations. Calculate the difference in cost for each of the methods.

You might decide that a maintenance program based on condition will be the most effective, but you do not have the funds to begin implementing it immediately. Are you able to implement a basic prescriptive maintenance program at the moment and then position yourself to move into CBM in the near future?

There will not be a one-size-fits-all “best” approach, and nothing drains an account quicker than ignoring the maintenance of your equipment (yes, there’s such as a thing). Take into consideration your personal circumstances and objectives, and make a wise choice. It’s among the most crucial business decisions you’ll ever make.