What is Preventive Maintenance? Types, Examples, and Benefits

Article Written by:

Muthu Karuppaiah

What is Preventive Maintenance? Types, Examples, and Benefits

Preventive maintenance signifies a systematic approach to equipment upkeep, where regular checks, servicing, and minor repairs are performed to keep machines running optimally. It's like going for a regular health check-up; small issues are detected early and resolved before they can escalate into major problems. By implementing a preventive maintenance strategy, businesses can minimize downtime, extend the lifespan of their assets, and maximize productivity.

Many organizations leverage Computerized Maintenance Management System (CMMS) software to streamline and enhance preventive maintenance strategies' effectiveness.

Why is Preventive Maintenance Important?

Preventive maintenance is the guardian angel of equipment health. It dramatically reduces the risk of sudden breakdowns, which can be costly in terms of finances and time. Preserving the equipment's condition paves the way for greater operational efficiency and longer machinery lifespan. In essence, preventive maintenance is the difference between smooth sailing and an untimely disruption in your business journey. By adopting a proactive approach to maintenance, organizations can reap these benefits, improve operational efficiency, and achieve long-term success.

Timely Maintenance Planning
A preventive maintenance schedule allows businesses to plan maintenance activities. By establishing specific maintenance intervals and tasks, organizations can ensure that inspections, servicing, and repairs are performed at the appropriate times. This proactive approach minimizes the chances of overlooking maintenance requirements and helps maintain equipment optimally.
Equipment Reliability and Performance
Regularly scheduled preventive maintenance helps maintain equipment reliability and performance. Adhering to a planned maintenance routine can identify and address potential issues before they cause significant breakdowns or malfunctions; This reduces downtime and ensures that equipment operates at its peak efficiency, leading to improved productivity and consistent output quality.
Asset Lifespan Extension
Implementing a preventive maintenance schedule supported by specialized software enables businesses to extend the lifespan of their assets. Equipment wear and tear can be minimized by performing routine maintenance tasks such as lubrication, calibration, and parts replacement; This prolongs the lifespan of the assets, reducing the need for premature replacements and maximizing return on investment.
Optimal Resource Allocation
Implementing a preventive maintenance schedule allows organizations to allocate resources more effectively. By planning maintenance activities, businesses can optimize manpower, spare parts, and equipment availability. Preventive Maintenance Software enhances resource allocation by providing real-time visibility into maintenance tasks, enabling efficient scheduling and reducing downtime.

Types of Preventive Maintenance

There are several types of preventive maintenance strategies that organizations can implement based on their specific needs and equipment requirements. Here are some common types:

Time-Based Preventive Maintenance

As the name suggests, Time-Based Preventive Maintenance involves performing maintenance tasks at set time intervals; This could be every week, month, year, or any other period that makes sense based on the specific piece of equipment and its usage patterns. An example could be changing the oil in a vehicle every 5,000 miles or checking fire extinguishers in a building every month.

Usage-Based Preventive Maintenance

Usage-based preventive maintenance relates to the operational usage of a piece of equipment; This could be after a certain number of production cycles, miles driven, or hours of operation. For instance, an aircraft may undergo a detailed inspection after several flight hours.

Condition-Based Preventive Maintenance

Condition-based maintenance is performed based on the actual condition of the equipment, as determined by regular monitoring and checks. This approach leverages sensors and other monitoring technologies to identify signs of wear or potential failure. For example, a motor might use vibration analysis to detect the onset of a bearing failure.

Common Examples of Preventive Maintenance Tasks

Some day-to-day illustrations of preventive maintenance include:

  • Lubricating machinery components.
  • Checking tire pressure in vehicles.
  • Cleaning air conditioning filters.
  • Inspecting and replacing worn-out parts in equipment.
  • Regular software updates to prevent security vulnerabilities.

How Does Preventive Maintenance Differ from Reactive Maintenance?

If preventive maintenance is the well-planned strategy in equipment management, reactive maintenance is the Hail Mary pass. Reactive or corrective maintenance involves addressing equipment problems as they arise without any prior planning. While preventive maintenance concerns foresight and early intervention, reactive maintenance concerns firefighting and damage control.

Key Steps Involved in Setting Up a Preventive Maintenance Program

Setting up a preventive maintenance program is akin to designing a roadmap for equipment wellness:

  • Start by inventorying your equipment and noting its maintenance needs.
  • Next, schedule regular inspections based on these needs.
  • Establish standard procedures for each maintenance task.
  • Train your maintenance team in these procedures.
  • Monitor and optimize the program based on real-world results.

Best Practices for Optimizing a Preventive Maintenance Strategy

Just as each ship requires a well-thought-out navigation plan, each preventive maintenance strategy requires careful consideration. Here are some best practices for charting a successful journey:

Prioritize Equipment
Not all equipment is created equal. Some pieces are more critical to your operations than others. Prioritize your equipment based on its importance and schedule more frequent maintenance for critical machinery.
Leverage Technology
Harness the power of digital tools like CMMS and IoT devices. They can streamline your processes, reduce human error, and provide valuable insights into your equipment's health.
Data-Driven Decisions
Use data from your CMMS to optimize your preventive maintenance schedule. Adjust the frequency of maintenance based on the historical performance of each machine.
Engage Your Crew
Your maintenance team is the backbone of your preventive maintenance strategy. Provide regular training, encourage feedback, and foster a culture that values preventive maintenance.
Continuous Improvement
Don't let your preventive maintenance strategy become stagnant. Regularly review and adjust your strategy based on your operations, equipment, or team changes. Consider it as an ongoing journey, not a destination.

IoT in Preventive Maintenance

IoT devices equipped with various sensors can be attached to machinery and equipment to collect data about their condition in real-time. This data might include temperature, pressure, vibration, humidity, acoustics, etc. The following are specific ways IoT supports preventive maintenance:

Condition Monitoring
IoT sensors continuously monitor the condition of equipment, detecting any parameters that deviate from their normal range; This helps identify potential issues before they lead to equipment failure.
Predictive Maintenance
The data collected from IoT devices can be analyzed to predict when a piece of equipment will likely fail; This allows maintenance to be scheduled just in time, preventing breakdowns and reducing downtime.
Automation of Data Collection
IoT devices automate the data collection process, providing more accurate and timely data than manual inspections and freeing up maintenance personnel to focus on higher-level tasks.

AI in Preventive Maintenance:

AI, particularly machine learning, plays a key role in analyzing the vast amounts of data IoT devices collect. Here's how AI contributes to preventive maintenance:

Predictive Analysis
Machine learning algorithms can analyze data from IoT devices to identify patterns or trends that indicate a potential equipment failure; This allows for predictive, rather than reactive, maintenance.
Fault Diagnosis
AI can also help diagnose the cause of equipment problems by analyzing historical data to identify patterns associated with specific faults; This can reduce the time spent on troubleshooting, leading to quicker repairs.
Optimization of Maintenance Schedules
AI can use historical data and predictive analysis to optimize maintenance schedules, ensuring that maintenance is performed when it's most cost-effective and least disruptive to operations.

When used together, IoT and AI form a powerful tools for preventive maintenance. IoT devices provide real-time, accurate data about equipment conditions, and AI analyzes this data to make accurate predictions about equipment failure, optimize maintenance schedules, and assist in fault diagnosis. This combination can significantly improve the efficiency and effectiveness of preventive maintenance, reducing downtime, extending equipment life, and saving costs.

Frequently Asked Questions Regarding Preventive Maintenance

Are There Any Specific Industry Standards or Guidelines for Implementing Preventive Maintenance?

There are numerous standards and guidelines for preventive maintenance, depending on the industry and the nature of the equipment. For instance, ISO 55000 provides a broad framework for asset management, including preventive maintenance. There are also industry-specific standards, such as API 653, for inspecting above-ground storage tanks in the petroleum industry.

How Does Predictive Maintenance Differ from Preventive Maintenance?

While preventive maintenance is scheduled based on the estimated or average life expectancy of equipment, predictive maintenance relies on the actual condition of the equipment. Predictive maintenance uses real-time data and sophisticated analysis to predict when a breakdown is likely to occur, and maintenance is then scheduled accordingly.

Are There Any Hybrid Approaches that Combine Different Types of Preventive Maintenance?

Yes, many organizations use a hybrid approach combining different preventive maintenance types. For example, they might use time-based maintenance for certain tasks, usage-based for others, and condition-based for critical equipment. The choice often depends on the nature of the equipment and the specific operational context.

How can Data Analysis and Monitoring Systems Support Different Types of Preventive Maintenance?

Data analysis and monitoring systems are particularly crucial for condition-based maintenance, where they provide real-time data that informs maintenance decisions. However, they can also support time-based and usage-based maintenance by tracking when maintenance is due or how much equipment has been used. Furthermore, the data collected through these systems can provide valuable insights for optimizing maintenance strategies.

Are there any Specific Industries or Sectors where Preventive Maintenance is Particularly Crucial?

Preventive maintenance is the lifeblood of any industry that relies on machinery or equipment. However, it is particularly crucial in industries where equipment failure can lead to catastrophic consequences, such as manufacturing, transportation, healthcare, and energy production sectors.

Bottom Line

In summary, preventive maintenance is a proactive approach to equipment management that aims to prevent failures, extend asset lifespan, improve reliability, and optimize operational efficiency. With Cryotos CMMS Software, organizations can easily Create and Manage Preventive Maintenance Schedules, ensuring that inspections and maintenance tasks are performed at the right intervals. The software facilitates the tracking of maintenance activities, generating reports and analytics to assess equipment performance, identify trends, and optimize maintenance strategies.

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Here From Our Esteemed Clients!

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

What do you like best about Cryotos?
Easy to access and data collection,user friendly, the technical team and the supporting team is excellent the way they are solving the issues ontime and the continuous training given by supporting team. I would like to promote the cryotos APK to other industries to use.

What problems is Cryotos solving and how is that benefiting you?
Easily we came to know which machine is problem and what is the issue. And we got the exact data of spare parts stock. Using cryotos APK our machinery maintenance is increased and now we are getting less machines problem.

Review from G2

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!

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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.

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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.

Mr. Sathyendran R.

What do you like best about Cryotos?
I am using this application right now for my service team, very good, user friendly, have lot of customisation in workflow and service reports. the team supported for initial implementation, They have good support team. Myself fully recommended this application.

What do you dislike about Cryotos?
Noting as of now seems all good

What problems is Cryotos solving and how is that benefiting you?
Cryotos application is solving our feild service team operations.

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Mr. kandasamy S.

What do you like best about Cryotos?
Excellent application for Maintenance activity like PPM,etc
Good team for develop our process as per our requirement like process,Standards,etc
Professional & very Supportive team.
Really appreciated for language change (English to Arabic).

What do you dislike about Cryotos?
There is no negative observation till now.

What problems is Cryotos solving and how is that benefiting you?
Scheduling & PPM for Maintenance Activity.

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Mr. Yap

What do you like best about Cryotos?
template are ready to use, minimal need for IT knowledge. support team are supportive in all aspects

What problems is Cryotos solving and how is that benefiting you?
We are still in the midst of experimenting all the functions in Cryotos, for now is the ease of using asset management and as a scheduler.

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Mr. Hari K. - Ram Leathers

What do you like best about Cryotos?
Asset Management - Is Very easy for us, which make us to easily complete the tasks.

We are able to schedule the tasks and at the same time able to capture the daily readings for the machine.

Meter Reading module provides the real time data monitoring for all assets.

The very specific feature of the software is "AMC Monitoring"

What do you dislike about Cryotos?
As of now this software provides a better solution for us.

What problems is Cryotos solving and how is that benefiting you?
Asset monitoring is very helpful.

Able to track the machine availability using the MTTR & MTBF details.

MIS Dashboard - Provides the breakdown information of all our machines.

The dahboards & reports generates the accurate details our assets.

They also provide the customizable dashboard option using Metabase.

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Dinex - Esteemed Clients of Cryotos
Māris A.

What do you like best about Cryotos?
We used many maintenance CMMS and only in Cryotos is functionality to build your own workflows for work orders and scheduled maintenance. With this CMMS we not need some separate analyzing system like Power Bi, Cryotos have already built-in Metabase system where we can easily build reports and visualizations for reports.

What problems is Cryotos solving and how is that benefiting you?
CMMS help us control all machinery brekdowns and factory problem. CMMS collet all data about our historical data, its help analize deviations. With this system we build all necessary processes which we need in our factory, which are work autonomous.

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Planys - Cryotos Esteemed Client
Aravindishwar k.

What do you like best about Cryotos?
Cryptos is very easy to use and user friendly which we can easily customise to our needs and while delivering the workprocess it's very convenient to use by the end user as well.

What problems is Cryotos solving and how is that benefiting you?
Cryotos saves our time and space thus act as a great inventory of data which will be accesed from anywhere any time and it helps us to track the work we have done all along it's a best CMMS software.

Read Complete Review on G2

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