Having a maintenance plan secures long-term success for the company as it enables to improve safety, reliability, and productivity. It is focused on improving the reliability and functionality of critical assets in an efficient and cost-effective manner. The strategy is effectively dynamic and must be updated periodically as circumstances change. The gearbox can fail when gear tooth damage accumulates due to abrasion or corrosion. same as predictive maintenance, just with an added layer of complexity. Most importantly, the implementation can be spread out in small increments. It is useful to consider maintenance strategy from a dual perspective: This model puts, quite properly, the asset at the heart of the maintenance strategy defining what is needed to achieve its optimum performance; and then around it is defined all the management tasks needed to provide the asset care strategy at the core. Maintenance strategies are often costly and require significant resources to implement and maintain. is based on identifying potential functional failures, , and the severity of their downstream effects (which is basically an. A predictive maintenance strategy is a more accurate version of condition-based maintenance. Much like annual or mileage-based service on consumer vehicles, preventative maintenance is often time- or usage-based, following your equipment manufacturers recommended schedule and servicing machines during planned maintenance visits. Could we find an organization where preventive maintenance is an ideal strategy for all of its assets? Test drive Limble's CMMS and increase your profits today! our complete guide to predictive maintenance, 5) Prescriptive maintenance strategy (RxM), Dan Miklovic from LNS research explained it great in, Lets say a piece of equipment is showing increasing bearing temperature. Reducing the number of hours required to complete the same level of maintenance. If not, these are only four types of maintenance strategies, so you have plenty of other options to consider. Common maintenance strategies include reactive, preventive, predictive, and reliability-centered maintenance. Occasionally review available maintenance data to see if your maintenance schedules can be improved and if everyone is following outlined procedures. 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. Each section will end up with a link towards an in-depth guide that discusses the respective maintenance strategy in more detail. It must be remembered that by the time equipment is in use, the inherent reliability of the equipment has been established. If a critical failure occurs, it can cause unnecessary delays in production that can cost more in lost production time than it would have cost to implement a more proactive maintenance strategy in the first place. Most importantly, the implementation can be spread out in small increments. B. Post-production Phase II . As we mentioned, RCM may encompass all of the other strategies depending on the equipment component and the available resources. Keep in mind that RCM is a complex process that feeds on maintenance data. This approach focuses on recognising the failures that compromise the system the most and adopt the best strategy for each critical asset. A good working relationship with the supplier of equipment is an important determinant of success in any reliability programme. maintenance decisions made, while poor calculation will cause the stoppage of production operation. Also, keeping them updated to maintain productivity in the most efficient manner. Sign up for a free trial and start experiencing eMaint's CMMS solution for yourself. It involves regular inspection, monitoring, and proactive measures to minimize equipment downtime and extend its lifespan. CBM usually requires an investment in a remote data gathering system and user training. Unfortunately, that is not how the real world works. The term maintenance maturity describes how well developed an operation's maintenance processes and systems are, and to what degree they deliver value for the wider operation. Cultural change can be difficult to grasp unless you break it down into pragmatic steps. Economical factors in choosing maintenance planning are crucial. The problem CBM tries to solve relates to the way wear and tear accumulate. Once the main sub-functions themselves are defined, the current level of capability in each of the areas can be assessed by looking at best practices that would be expected to be seen in use to accomplish these tasks. This type of preventative maintenance is carried out at regular intervals, such as biweekly or at the beginning of each month. Scratch that. Examples include. Track and store inspection reports. The following blog post shares the four primary maintenance strategies in use today, along with their advantages and disadvantages. The belt itself can slip because of insufficient tension. While in some cases that might be redundant, you can technically use RbM to identify your critical assets, and then pull those assets through the RCM process to select prevention methods and create the maintenance schedule. Industrial PdM can be used for all equipment, or it can be reserved for your most critical assets. Maintenance strategies ensure that all required maintenance tasks are completed in a timely manner, reducing the risk of operational failure or downtime. This is not as difficult as it may sound. A maintenance strategy is a system developed to keep your facility's assets in the best shape, reduce expenses and downtime, and increase productivity. Things start to break left and right. For example, a facility that is likely to experience failure if vital industrial parts that are at high risk of water contamination exposure. This approach, when applied to all physical assets, can literally ruin a business. Its really perfect, esp. 4. What is predictive maintenance? For more info, read our full guide on preventive maintenance. You can just drag and drop tasks to quickly change due dates and reschedule work. 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. Detect when the equipment is starting to degrade and replace or recondition at a time convenient to the operation (predictive maintenance). There are many different approaches that you can mix and match, depending on your assets, your industry, and the size and experience of your maintenance team. via condition monitoring and machine learning algorithms that use a model to fine-tune the allocation of physical resources. This helps to avoid unplanned downtime and equipment failure. They should infuse these practices into the culture of the organization. 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. He says that's his plan in Las Vegas as well. Preventive maintenance is critical to ensure long life and great gear performance. Maintenance teams cannot be everywhere at the same time. Any of the four can be the most expensive if it's the wrong one for you and your asset. Run to fail maintenance (RTF) is a deliberate choice to let an asset fail before repairing it. Maintenance strategies may be inflexible, meaning they may not be able to adjust to changing conditions or requirements. How to build an asset management policy Reliability-Centered Maintenance (RCM) is a corporate-level maintenance strategy designed to optimize maintenance programs by establishing safe minimum levels of equipment upkeep. Preventive Maintenance: Preventive maintenance is a strategy that involves regularly scheduled inspections, tests, servicing, and replacements of necessary components and parts, before they actually fail or malfunction. One of the most important tools in maintenance planning is risk-based maintenance (RBM). As a low-cost option, preventive maintenance is still the best strategy for moving away from reactive maintenance. Its framework helps you select the most appropriate prevention methods. These metrics, which are early indicators of asset wear, can then be compared to the machines baseline. Where is your maintenance department right now? 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. Aghezzafa, E.H., Jamalib M.A., Ait-Kadi D. (2007), Bechtel, J., Ganesan, S., Prajapati, A. They vary in complexity, effectiveness, and implementation cost so you do not want to make this decision without understanding what each brings to the table. That information is then used to create more efficient maintenance schedules. It still relies on reactive, preventive and predictive maintenance. Best practices are only useful where they contribute to the performance of low downtime of key assets or allow the work to be done more efficiently. Reliability-Centered Maintenance, or RCM, responds to non-linear failures by providing analytics on all potential failure modes and building a custom plan to address each parts stability. One key element of proactive maintenance strategies is the use of condition monitoring technology, which allows maintenance teams to plan maintenance around data from the machine itself. 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. Dan Miklovic from LNS research explained it great in his post: Lets say a piece of equipment is showing increasing bearing temperature. Developing a robust maintenance strategy requires weighing the benefits and costs it brings to the table. It is fairly easy to set up and doesnt require a lot of training. changing the filter every couple of months; changing the oil every three weeks, after X amount of working hours; every X production cycles. An important number of failures stem from design deficiencies in some way, and the ability to influence reliability is greatest at the early stages of a project. You also should have the means to capture the conditions found at each inspection. All rights reserved. Replacing light bulbs usually happens when they fail (RTB), engine oil should be changed regularly (PM) while many components might have an indicator when they start to exhibit unusual behavior (CBM). The technical overview can follow once the economic considerations are accepted. Save my name, email, and website in this browser for the next time I comment. Keeping the asset clean and ensuring that the equipment they use is running within proper settings are the first steps in good asset management. Strategic plans prepared to maintain capacities and facilities comes under Maintenance Planning. You will also be able to manage incoming work requests, change task priorities, reschedule and reassign specific tasks, and track exactly how much maintenance resources are you spending on each asset. According to our 2021 maintenance report, preventive maintenance is the most popular asset management strategy. Sunaero, a Lyon-based company with expertise in fuel leak detection and fast curing for sealant repair, is proceeding with a strategy of diversification. The criticality of an asset is determined using a risk (a.k.a criticality) matrix. The company is offering complete services . When selecting a maintenance strategy, we can confidently say that being proactive is better than being reactive. When its time to present the strategy to the board, using the right language helps the maintenance manager to build a credible case for change. Defining an effective maintenance strategy for an organisation is a wider task than simply deciding how to maintain each individual asset. Slack, N., Chambers S., Johnston R. (2007). One downside to this approach is that it does not take ownership costs into consideration. The more data it has, the more accurate the model is in predicting failures. However, reactive maintenance is not a practical solution in the long term for repairable assets. It's important to develop a mix of different strategies to properly maintain your assets and ensure that they remain in working . Start with preventative maintenance and move your way up. He hopes to break ground on this project . As such, it is easier to justify the investment into condition monitoring and predictive technology to keep an eye on your highest-priority assets. Your email address will not be published. this insightful guide on prescriptive maintenance, Maintenance strategy comparison summarized, Applying the right maintenance strategy to each asset. A much better question would be: How can we address these specific failure modes that asset X has? Selecting the right prevention methods for identified failure modes (or technology to predict them) is easier said than done. Not all failure modes are created equal. Capabilities are demonstrated by the beneficial use of maintenance best practices, and the overall maintenance strategy able to be employed by the maintenance operation significantly changes with the development of more capabilities. Interested to see how easy facilities can be? to schedule work based on the current condition of the asset. A guide to comparing maintenance strategies Compare maintenance strategies and get a framework for deciding when to use them on your equipment with this in-depth guide. It is a maintenance strategy based on continual monitoring and renewal so that you always have plant and equipment that are in good condition, along with high availability and reliability. In a nutshell, that's what a maintenance strategy aims to achieve. Rinse and repeat. 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. Facility maintenance software can monitor equipment performance and identify patterns to predict when a breakdown may occur. The deferred maintenance backlog starts to grow and operational issues become unbearable. On the other hand, prescriptive analytics tells you that if you slow the equipment down by Y%, the time to failure can be doubled, putting you within the already scheduled. The maturity model shown in Figure 2 shows the generalised progression of a maintenance operation as it gains more and more capabilities. You might even consider switching maintenance approaches for specific assets and failure modes. On the other hand, prescriptive analytics tells you that if you slow the equipment down by Y%, the time to failure can be doubled, putting you within the already scheduled maintenance window and revealing whether you can still meet planned production requirements. Over the years, advancements in sensor and IIoT technology facilitated the evolution of maintenance strategies. Copyright 2023 Limble CMMS. However, a. Nonrepairable assets like light bulbs and assets that are near the end of their life cycle can just be replaced after they break down. Improve communication. Linked to the maintenance maturity, the capability model indicates where best practices are used to accomplish tasks within the maintenance management remit. Maintenance strategies fall into one of three types: corrective (reactive), predictive and preventive. Similarly, if there are no maintenance planners, dont expect well planned and efficiently executed maintenance. Industries need reliability programs to ensure profit in terms of better utilization of existing production resources. Every maintenance task needs the right tool to be done properly and EAM software is the best tool for managing your equipment maintenance strategy. Types of Maintenance: The 4 Main Maintenance Strategies. Likewise, it also carries additional costs and complexity. 1M task - Greasing. Prescriptive maintenance strategy represents the most advanced approach to asset maintenance. What Is Planned Maintenance Optimization (PMO)? You can check Limbles pricing plans and start a trial here. From the perspective of the wider operation, the cost of corrective maintenance usually far exceeds the costs of any realistic preventive maintenance effort. There are too many moving parts to do everything manually. We will briefly explain how each strategy works and proceed to evaluate them based on the following factors: We will include a few custom graphics to help you visualize the relative difference between those factors. 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. The four main maintenance strategies are run-to-failure, preventive, condition-based, and predictive. very high upfront costs with the highest potential ROI over time. How far does the operation exploit known best maintenance practices, and how does it compare against others along the maturity curve? Tunbridge Wells However, this can lead to excessive maintenance like replacing parts that could still be used for a while. Defining and implementing the appropriate maintenance strategy for your business, i.e., the most effective and efficient ratio of the three above methods will require you to gather, analyze and share relevant data in an organized and coherent fashion. Knowing probability of failure is useful to adjust maintenance schedule. Let us handle your facility and job management needs and help your organization save time and money. For example, resource optimization shows how predictive maintenance allows maintenance planners and managers to allocate and use their maintenance resources more efficiently than if they are running reactive or preventive maintenance. With their exceptional accuracy and versatility, RVmagnetics' MicroWire sensors are able to transform industries and reshape the future of maintenance strategies. Preventive maintenance is a cost-efficient maintenance strategy intended to reduce downtime and extend the lifespan of all machinery. Implementing effective maintenance strategies can prevent costly breakdowns, reduce downtime, and optimize the . Comparing maintenance management strategies We spend a lot of time extolling the virtues of preventive maintenance, but it's far from the only maintenance strategy out there.
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what is maintenance strategy
