Most Utilized Maintenance Strategies

Article Written by:

Muthu Karuppaiah

Created On:

December 16, 2022

Most Utilized Maintenance Strategies

Table of Contents:

The cost of inaction is increasing in the present-day industrial environment. To the facility and asset managers, the issue is obvious: unexpected downtime, increasing equipment prices, and business inefficiency are not merely a maintenance problem anymore but a threat to the profitability of the business. Trusting old-fashioned techniques or fragmented spreadsheets can continuously have the teams in firefighting mode, as they strive to keep critical assets in operation as budgets run out.  

Nevertheless, there has been a major change during the past ten years. Maintenance is no longer considered a cost center or some kind of fix-it department gathered in the basement. It has become a business pillar of strategic success. It is no longer about repairing failed machines but about "Asset Performance Management," a more proactive strategy that will help predict failures, extend the life cycle, and identify the value concealed within each piece of equipment.  

It is in this regard that Cryotos comes in. The more strategies are not reactive but data-driven, the more complicated it is to manage them. Cryotos CMMS fills this gap by offering the intelligent digital core required to transform these sophisticated maintenance plans into a day-to-day operational reality, such that your day of conversion from fixing to optimizing is an easy and scalable affair.  

What is Maintenance?

In essence, maintenance is the overall collection of actions necessary to maintain an asset, that is, a manufacturing robot, an HVAC system, or city infrastructure, in good condition.

Although the key aim is to reduce failures and rectify the performance degradation, contemporary maintenance comprises the value preservation as well. It guarantees that all equipment remains functional for its intended purpose throughout its life cycle. Maintenance can be broadly classified into two:  

  • Corrective: Restoring an asset to its operational state after a failure or performance dip.
     
  • Preventive: Proactive tasks performed regularly to prevent failures before they occur.  

Why is a Robust Maintenance Strategy Important?

Having a maintenance strategy is not only a nice-to-have but also a business imperative.  

  • Cost Efficiency: Good maintenance prolongs the life of assets, making them valuable before replacement is expensive, and in cases of accident, emergency repairs are very costly.
     
  • Safety & Compliance: Properly maintained equipment guarantees the safety of the employees and also adherence to high standards of industry regulations.  

  • Operational Continuity: There are unexpected failure points that result in spillovers across the entire supply chain. An effective strategy will reduce such surprises, which will guarantee continuity of business.  

A maintenance strategy has to be specific to the asset, the environment it is operating in, and the performance objectives of the organization to be effective.  

The 6 Most Utilized Maintenance Strategies

Maintenance is not a "one-size-fits-all" discipline. Most leading organizations use a hybrid approach, choosing certain strategies to use depending on the criticality of the assets, their replacement cost, and the impact of failing.  

Here is a breakdown of the six strategies dominating the industry today:  

1. Reactive Maintenance (Run-to-Failure)

Being confused with the idea of bad planning, reactive maintenance is a fair approach to use in the right methods. The model does not involve carrying out any maintenance until the asset ceases to work.  

  • How it works: You simply run the asset till it fails, and then it is repaired or replaced.  

  • Ideal Use Case: Noncritical assets that are cheap in capital and contain no form of safety risk (e.g., changing light bulbs in a hall or changing a computer mouse).  

  • Pros: It is less expensive to set up; no planning or monitoring of conditions is required.  

  • Cons: Uncontrolled failure; increased long-term cost with disastrous failure; expedited delivery of parts.  

2. Preventive Maintenance (Time-Based)

This is the minimum requirement of the majority of the facilities. Preventive Maintenance (PM) is based on some kind of calendar or use trigger (e.g., every 3 months or every 500 cycles).  

  • How it works: Maintenance tasks are scheduled at regular intervals to prevent degradation, regardless of the machine's actual condition.  

  • Ideal Use Case: Assets with predictable wear patterns where failure is age-related (e.g., changing HVAC filters, lubricating motors, or fleet vehicle oil changes).  

  • Pros: Extends asset life; makes budgeting and scheduling predictable.  

  • Cons: Risk of over-maintenance—you can end up re-changing parts that have not yet worn out, and this is a waste of money and time on the part of the technician.  

3. Predictive Maintenance (PdM)

Predictive maintenance is the transformation from time-based to condition based. It is based on the real health of the machine instead of on a schedule.

  • How it works: Sensors and IoT devices are used to track real-time data, i.e., vibration analysis, thermal analysis, or oil analysis, to identify the early signs of a failure.

  • Ideal Use Case: Critical, high-valued resources where the unexpected downtime will be catastrophic.  

  • Pros: Removes unneeded maintenance; identifies problems before they can destroy assets; makes the most of available assets.  

  • Cons: It is more expensive to set up sensors and software at the beginning; it needs data analysis skills.  

4. Prescriptive Maintenance (RxM)

When predictive maintenance can inform you when something will be broken, prescriptive maintenance can inform you how to handle it. This is the state of the art of Asset Performance Management (APM).

  • How it works: This strategy uses AI and machine learning to process data to come up with particular recommendations.  

  • Ideal Use Case: Complex, automated manufacturing environments or smart factories with mature data ecosystems.  

  • Pros: The decision-making process is automated; the optimality of the operations dynamically allows avoiding downtime without human intervention.  

  • Cons: It is costly and consumes powerful historical data and AI implementation.  

5. Corrective Maintenance

Corrective maintenance is often confused with reactive maintenance, but there is a nuance: it focuses on the act of restoration.  

  • How it works: This is maintenance performed to identify, isolate, and rectify a fault so that the failed equipment can be restored to an operational condition. It can be a planned or unplanned breakdown.  

  • Ideal Use Case: Resolution of non-emergency problems identified in the regular check-ups before they turn out to be an acute failure.  

  • Pros: Special-purpose solution of particular problems; makes the most of parts.  

  • Cons: Still causes disruption of service; may cause secondary damage when the correction is not administered very fast.  

6. Reliability-Centered Maintenance (RCM)

RCM is not a maintenance activity per se —it is a strategy. It is the governing logic that determines what choice out of the above strategies to employ on what asset.  

  • How it works: You perform an extensive study of all the assets to get the failure modes and effects. You then give it the most cost-efficient maintenance plan.  

  • Ideal Use Case: A big facility with a huge maintenance budget whose assets are in the thousands and require optimization.  

  • Pros: Eliminates waste while directing resources to essential equipment maintenance, which results in better safety standards for the entire plant.  
  • Cons: The first analysis stage requires extensive time and work to complete.  

Streamlining Your Strategy with Cryotos CMMS

The current facility needs automated systems because manual strategy management through spreadsheets and paper records has become unworkable. The solution to this problem comes from Cryotos CMMS (Computerized Maintenance Management System).  

Cryotos provides a comprehensive, cloud-based platform that allows you to:  

  • Automate Work Orders: The system enables users to schedule Preventive maintenance tasks through automated work order processing.  

  • Integrate IoT Data: connect sensors for real-time predictive maintenance alerts.  

  • Track Assets: monitor the lifecycle and costs of every piece of equipment.  

  • Analyze Performance: Use data-driven reports to refine your strategies (RCM).  

Whether you are managing a manufacturing plant, a healthcare facility, or a fleet of vehicles, Cryotos scales to meet your specific needs.  

Conclusion

The most effective maintenance solutions require organizations to use both predictive tools and preventive maintenance schedules through their maintenance programs. The organization needs advanced software systems because it needs to handle hybrid operations that exceed its spreadsheet capabilities. The Cryotos CMMS system makes complex tasks easier to manage. Our platform functions as a central hub that enables you to automate processes while decreasing operational downtime and transforming maintenance data into practical business solutions.  

Ready to stop firefighting and start optimizing? Book a Free Demo with Cryotos Today and discover how smart maintenance management can drive efficiency for your business.

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