In recent years, new technologies have created new ways to predict equipment failure with unprecedented accuracy. This has led to the emergence of four main types of preventive maintenance, each based on the concept of planned maintenance, but organized and scheduled differently to suit different business purposes. Usage-based preventive maintenance is triggered by the actual use of an asset. This type of maintenance takes into account the average daily use or exposure to environmental conditions of an asset and uses it to forecast a deadline for a future inspection or maintenance task.
Predictive maintenance is designed to schedule corrective maintenance actions before a fault occurs. The team must first determine the condition of the equipment to estimate when maintenance should be performed. Then, maintenance tasks are scheduled to prevent unexpected equipment failures. It is important to note that predictive maintenance is a more evolved form of preventive maintenance.
Both types try to proactively anticipate and prevent mechanical failures. However, predictive maintenance takes the concept even further. With preventive maintenance, general information about a make and model of machine is used to formulate rough estimates of when regular maintenance should be performed on it. Predictive maintenance, on the other hand, is considerably more accurate and requires a larger amount of data.
Information about the expected lifecycle of that equipment model is combined with historical data about the performance of that particular unit. This allows operators to know with certainty when system failures will occur and reduces unnecessary repairs. Any type of maintenance that is not reactive (i.e., an answer to a problem, faulty equipment, technology, etc.) is considered preventive. These include time-based, usage-based, predictive, and prescriptive maintenance. Now, let's take a closer look at each one in detail.
Time-Based Maintenance
Time-based preventive maintenance involves scheduling regular inspections and repairs for equipment and machinery based on predetermined intervals such as hours used or calendar time.To support this type of maintenance, it's also a good idea to keep detailed notes about past breakdowns and problems with tools and equipment, so that you have a better idea of what systems and equipment might need some extra care.
Usage-Based Maintenance
Usage-based preventive maintenance involves tracking usage (that is, equipment monitors, operating hours, production cycles) for machinery or equipment used every day. This type of preventive maintenance is especially relevant if the equipment does not automatically produce tickets or notifications when a certain number of operating hours are reached.Predictive Maintenance
Predictive preventive maintenance relies on sensors to capture information about equipment (i.e., temperature sensors or vibration sensors) and generally it is specific to technology that can trigger work orders if a machine or appliance needs an inspection or update. Predictive maintenance involves monitoring the condition of essential machinery to track performance and detect potential defects that could cause system failure.Prescriptive Maintenance
Prescriptive preventive maintenance uses advanced analytics, machine learning, and artificial intelligence to generate predictions about maintenance and also act accordingly. This type of preventive maintenance makes recommendations to improve system operations and tracks on its own to draw up a work order and oversee the entire process.Benefits & Pitfalls
Now that you understand more about the different types of preventive maintenance, let's discuss the benefits and potential pitfalls of standard preventive maintenance practices.Condition-Based Monitoring
Condition-based monitoring involves looking at the state of an asset to identify what type of maintenance it requires and when it requires it.You would look for signs of an imminent failure which would indicate that it is time to perform a tune-up to maintain its functionality at an optimal level.
Risk-Based Maintenance
Risk-based preventive maintenance applies the Pareto principle also known as the 80-20 rule. According to this principle 80 percent of faults come from 20 percent of causes. As such you should focus on these areas to minimize malfunction.Predictive Maintenance
Predictive preventive maintenance involves inspecting the condition of your assets with the help of sensor devices.Calendar-Based Maintenance Strategy
The calendar-based preventive maintenance strategy is suitable for short-term assets such as fire extinguishers gate motors pumps etc. One advantage of using this strategy is that it provides better preparation for the next task.It lets you know all the parts supplies and labor needed for the job to be done.
