How to Effectively Transform Your PM Schedule from Time Based to Condition Based and What Are Its Benefits?

As with most things in life, it is easier and cheaper to be proactive than reactive. This is especially true when it comes to maintenance. Reactive maintenance (Run to Fail maintenance) is fixing something only after it has broken down. Proactive maintenance is taking the necessary steps to prevent breakdowns before they happen. Not only does proactive maintenance save you money in the long run, but also minimizes downtime and keeps your equipment running at peak efficiency.

How to Effectively Transform Your PM Schedule from Time Based to Condition Based and What Are Its Benefits?

Preventive Maintenance (PM) is an important part of any reliability program as it comes under proactive maintenance. It is a scheduled effort to detect and correct potential problems before they cause failures or unplanned downtime.

The goal of preventive maintenance is to keep equipment running at peak performance and to extend its useful life. Time-based preventive maintenance is the most common type of PM, but it is not always the most effective.

Condition-based preventive maintenance (CbPM) is a more effective approach that uses condition monitoring data to determine when PM is needed. CbPM can be used to schedule PM based on equipment conditions, rather than on time or usage.

This blog explains the difference between time-based and condition-based preventive maintenance and how to effectively transform your PM schedule from time-based to condition-based.

The conventional wisdom around preventive maintenance

Preventive maintenance (PM) has long been the conventional wisdom around manufacturers to prevent equipment failure, loss in production, and potential safety risks. It involves the execution of regularly scheduled maintenance, such as checking and replacing components and ensuring that the equipment is operating correctly, to ensure that it runs correctly and efficiently. Time-based preventive maintenance typically relies on a maintenance technician’s experience and knowledge to determine when and how often certain parts need to be replaced, as well as when to perform periodic inspections.

Unfortunately, time-based preventive maintenance schedules can often be inefficient, especially as the size of the operation increases and the number of pieces of equipment expands. They often result in over-servicing or under-servicing and can be costly due to the costs of manual labor, parts, and equipment downtime. In addition, time-based schedules don’t consider changes in the condition of the equipment over time, which further reduces their efficiency.

The importance of data in driving effective decision making

In this ever-evolving digital world, data is becoming increasingly important for effective decision making, particularly in the realm of preventive maintenance. Real-time data from condition monitoring systems allows manufacturers to pinpoint maintenance issues before they become expensive problems. This data-driven approach provides much needed visibility into the current health of their equipment, which is critical in preventing costly downtime.

Condition monitoring systems use a variety of sensing technologies to collect data on the condition of the equipment over time. This data can be used to determine the health of the asset, predict failure, and optimize maintenance scheduling. In addition, advanced analytics and machine learning can be used to analyse the data to identify potential problems. As a result, manufacturers can schedule maintenance at the right time, reducing costly downtime and minimizing the costs associated with replacement tasks.

How to make the shift to condition-based preventive maintenance

Making the shift from time-based to condition-based preventive maintenance requires a few steps. First, you need to implement a condition monitoring system. This involves selecting the right sensors for your application, ensuring that the system is properly installed and calibrated, and training personnel on its use. Once the system is in place, you can begin collecting and analysing real-time data on the performance and condition of your equipment.

Next, you need to develop a maintenance strategy based on the data. This involves identifying the potential failure modes of each asset and developing maintenance tasks to address them. Once the tasks have been identified, you need to develop a maintenance schedule that takes into account the predicted performance and reliability of the equipment.

Finally, you need to ensure that your maintenance technicians are properly trained on the use of the condition monitoring system and the new maintenance strategies. Training should include instruction on how to use the system to monitor the condition of the equipment, how to interpret the data and identify potential malfunctions, and how to perform the appropriate preventive maintenance tasks.

Why this change is worth it for your business

Condition-based maintenance is well worth the effort for most businesses. It offers several benefits that make it superior to time-based maintenance schedules. For one, it’s much more efficient and cost-effective. With condition-based maintenance, you’re no longer wasting time and money on unnecessary maintenance tasks. You’re only performing the maintenance that’s necessary when it’s necessary.

Condition-based maintenance also reduces maintenance costs by extending the life of your equipment. By proactively monitoring and addressing potential failure modes, you’re able to prevent costly outages and extend the life of your equipment. In addition, condition-based maintenance helps you to reduce inventory costs by ensuring that you have the right parts and components on-hand to perform necessary maintenance tasks.

How to get started with condition-based preventive maintenance

Making the switch from time-based to condition-based preventive maintenance can seem daunting. But with the right tools, it’s a fairly straightforward process. The first step is to evaluate your current maintenance strategy and determine which components are best suited for condition monitoring. While all components can be monitored for condition, it’s wise to focus your efforts on the assets that are most critical to the success of your operations.

Next, you need to select and install the appropriate sensors. This involves researching the available options, testing them in your environment, and selecting the ones that are best suited to your application.

Then, you can begin collecting data and analysing it to identify potential failure modes. This helps you to identify the maintenance tasks that should be performed, as well as the frequency with which they should be performed.

Finally, you need to implement the new maintenance schedule and train your maintenance technicians on the use of the new system. This includes training them on how to use the condition monitoring system, interpret the data, and perform the necessary preventive maintenance tasks.

Computerized Maintenance Management System (CMMS) and Condition Based Maintenance (CBM)

A Computerized Maintenance Management System (CMMS) is a piece of software that helps you plan, track, and optimize your maintenance operations. A CMMS can automate and streamline all the tasks associated with keeping your equipment in good working order, from creating and scheduling work orders to tracking inventory and stock levels.

A CMMS can also help you make the switch to condition based preventive maintenance (CBM). CBM is a maintenance strategy that focuses on monitoring the condition of your equipment and catching problems before they cause downtime. This can help you reduce your overall maintenance costs and improve your equipment uptime.

Wrapping up

In today’s manufacturing landscape, time-based preventive maintenance schedules are no longer sufficient to ensure the reliability and efficiency of your equipment. To ensure that your equipment is running optimally and to reduce the costs associated with maintenance, it’s important to implement a condition-based preventive maintenance schedule. Making this shift is worth it for your business, as it can significantly reduce maintenance costs and extend the life of your equipment.

If you’re looking to make the switch to condition-based preventive maintenance, the steps outlined in this blog post should have you off to a good start! Reach out to the Cryotos CMMS team to learn how we can help you switch from time based maintenance to Condition Based Maintenance (CBM) with our software.

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What Do Our Clients Says ?

Amrapali Exports - Esteemed Clients of cryotos
Anuraj Sharma - Maintenance Manager

The best thing about Cryotos CMMS software is that it always tells me when something needs to be fixed - before it breaks and cost me a fortune!

The software is very user-friendly, and even if I don't know how to do something, the support team is always there to help me out.

Most importantly, unlike other such software, Cryotos is editable and hence the user can modify how the software works as per their need, we made several changes in the workflow & flowchart with the help of development team.

I don't know what I would do without Cryotos! I've been using it for years, and it has saved me so much time and money. I highly recommend it to anyone who wants to manage their assets efficiently.

Resil Chemicals - Esteemed Clients of Cryotos
Jeevan Belliappa - Head, Information Technology

Since we've been using Cryotos CMMS Software, our asset maintenance management has been running more smoothly than ever. We're able to track and optimize our preventive maintenance with ease, thanks to the customized process workflow. This has been a lifesaver for our team!

The Cryotos CMMS software has allowed us to manage our assets more effectively and efficiently. It has helped us to improve our asset utilization. The software is user-friendly and easy to navigate, and the support team is always quick to help with any questions we have. We're very happy with the results we've seen so far and we're confident that we'll continue to see improvements in our asset management as we use the Cryotos CMMS software.

Planys - Cryotos Esteemed Client
Antony Jacob Ashish - Lead, R&D

Cryotos goes above and beyond when it comes to customer satisfaction. Planys Technologies use Cryotos for preventive/ corrective maintenance of our critical systems and not once did we face a problem that was not dealt with immediately. The team is extremely professional and helpful. We can rely on Cryotos when it comes to the operations and processes.

Thanks to the whole team for the amazing performance and thought leadership. It's rare to see teams that can put themselves in the customer's shoes and think from their perspectives - Cryotos team doesthat and more.

We recommend Cryotos if you are looking to put an end to your preventive maintenance problems and sign up with them!

Thanks to the team for an awesome job.

Xpert IFM - Esteemed Clients of Cryotos
Siva Shankar - AGM, (Operations & BD)

On behalf of Xpert FMS we would like to express our sincere appreciation for the excellent support Cryotos team have provided us for our building and facility management. Cryotos has always provided support that is timely and meets our expectations. Professionalism and quick response are the hallmarks of this team.

Sincere appreciation for the team's brilliant performance and wish them continued success. We highly recommend Cryotos as they have executed well on all assigned tasks and continue to outperform.

Thanks to all the hard work, our lives have become easier.

ST Jude India Childcare Centers - Cryotos Esteemed Client
Mukesh J - CIO

We are able to raised the workorder and tracking of these till the closure as helped us to provide better services our beneficiaries. Workflow-based work order management has helped us to define processes for each locations separatley. System provide notification once order is raised for assignment to engineer.

Maspro - Esteemed Clients of Cryotos

This CMMS software is top-notch! I can't believe how much it has helped me with my facilities maintenance management. Customized reports and business intelligence have been invaluable in making better decisions.

The software offers a great deal of customization for each organization's specific needs. They are always updating the software with new features and improvements, which is great. The support team is fantastic - they are always quick to help with any questions or problems we have. This software has definitely made my life a lot easier! It's so easy to use and it's really helped me keep track of all my maintenance tasks in one place. I would definitely recommend it to anyone looking for a CMMS platform.

Al Zain Farms LLC - Esteemed Clients of Cryotos
Mr. Vishnu S Nair

Since we've started using Cryotos, our team has been able to stay on top of all the various SOPs. Checklists and safety procedures are now easily accessible to everyone, and we can quickly reference them whenever we need to. The software has definitely helped to improve our team's communication and efficiency. Plus, the fact that it's cloud-based means we can access it from anywhere, which is a big plus. It has been a great help in keeping everyone on the same page and up to date with the latest procedures.

Dinex - Esteemed Clients of Cryotos
B S Vijaya K. - Maintenance Engineer

At starting it felt some what difficult for scheduling but now it made to easy access.

Review from Capterra

Korrun - Esteemed Clients of Cryotos
Nithin G. - Maintenance Incharge

Overall: Nice Software
Pros: Scheduling, work order creation, asset inventory, records.
Reasons for Choosing Cryotos: Compared to other products it's easy to use and easy to understand the feature.

Review from Capterra

Aptiv8 IT Solutions
Hashim - Business Project Manager

This CMMS software is top-notch! I can't believe how much it has helped me with my facilities maintenance management. Customized reports and business intelligence have been invaluable in making better decisions.

The software offers a great deal of customization for each organization's specific needs. They are always updating the software with new features and improvements, which is great. The support team is fantastic - they are always quick to help with any questions or problems we have. This software has definitely made my life a lot easier! It's so easy to use and it's really helped me keep track of all my maintenance tasks in one place. I would definitely recommend it to anyone looking for a CMMS platform.

Gurit - Esteemed Clients of Cryotos
Mr. Mohanmurali R

I recently purchased Cryotos CMMS Software for asset management needs at my organization and after a few months of testing and monitoring, I'm incredibly pleased with the results. The software is user friendly, accessible and the design is very intuitive. It covers all the aspects of managing maintenance and repair, starting from preventive maintenance and standardizing operation cycles, to scheduling and streamlining workflows. I am highly satisfied with the performance and the range of features offered by Cryotos. Highly recommendable!

Metro Tyres - Esteemed Clients of Cryotos
Mr. Sanjay Beri

Before using Cryotos, asset management and maintenance seemed like an uphill task for my team. Manual processes laden with human errors did not work for us at all. We decided to go with Cryotos after checking out similar products in the market.

The user interface of the software is intuitive and easy to use, making it simple to navigate through the different features and functionalities. I particularly appreciate the ability to track all assets in real-time, allowing me to keep a close eye on their performance and maintenance needs.

Customized work order and workflow creation has reduced the needs to always follow a particular template. Depending on our needs we can create tailor made workflows to suit our requirements.

I highly recommend Cryotos to anyone who would like to unburden themselves of maintaining and managing their critical assets.

Dinex - Esteemed Clients of Cryotos
Mr. Yuksel Aksin

As a customer of Cryotos CMMS software for asset management needs, I must say that I am thoroughly impressed with the features and functionality offered by the platform. Cryotos CMMS software has made managing my assets a breeze, and I no longer have to worry about missing maintenance or inspections.

One of the standout features of Cryotos CMMS software is the ability to generate work orders and schedule maintenance tasks. This has made it easy for me to stay on top of maintenance and repair tasks, ensuring that my assets are always in optimal condition.

The software also allows me to track inventory levels which has streamlined my inventory management process. The ability to generate reports and analyze asset performance data has also been invaluable in helping me make data-driven decisions about my assets. Overall, I would highly recommend Cryotos CMMS software to anyone looking for a reliable and efficient asset management solution.

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