Do you even think of any industry which can afford the equipment failure? The answer will be none. Based on a study, 80% of technical human resource energy generally stays occupied in reactive maintenance issues. Almost every day, they had a situation where one or another piece of equipment is not working, and due to that, the operations get hampered. Sometimes these small maintenance issues can cause some big problems. If you see the business history, you may find such incidents where their major loss has a root cause: a small equipment failure or oversight of a maintenance need.
As a part of the solution, an approach has been developed to perform maintenance before it’s needed. It’s popularly known as the Preventive Maintenance approach.
Let’s check out what Preventive Maintenance is and how it can be useful to businesses.
What is Preventive Maintenance?
Eliminating equipment failure is not in human control. However, with Pre-planned maintenance and a systematic repair schedule, you can reduce the repair frequency to a minimal level. This approach of pre-planned maintenance before the actual failure happens, called Preventive Maintenance. The preventive maintenance approach reduces premature asset breakdowns, ongoing operationality, a safe work environment, and saves a huge amount of money in maintenance and repair costs and costs arising due to equipment failure.
Why does your Business need Preventive Maintenance Software?
An organization’s most destructive accidents, operational deficiencies, and delayed production schedules are majorly caused by unplanned maintenance systems and poor internal communication. Let’s understand the relevant case.
As per a study, an organization had a set of machinery with a major dependency for the production of that Textile unit. But, the organization faced machine downtime now and then because their production got delayed and the estimated delivery cycle ran behind the promised dates, as they were following a reactive maintenance approach. As time grows, technicians become experienced with such issues and know when and what issues arise and how to resolve them. But the organization has a high turnover ratio and none of the technicians has documented any fault or the repair procedure for the knowledge of future recruits. Hence, failure kept on coming and the organization lost its reputation in the market, and due to the high maintenance cost, eventually, they had to shut down their business.
Instead of a reactive maintenance approach, issues can be resolved if they followed the Preventive Maintenance approach before it happens and business could be saved. That is why most businesses nowadays practice Preventive maintenance within the organization.
Let’s see the top three reasons why your business needs Preventive Maintenance software.
Upgraded Operational Efficiency
When equipment faces a downtime, if a reactive maintenance approach is practiced, you will need a handsome amount of time to get it repaired; till then, your employees are free and waiting for the work to start again, but their pay doesn’t stop, your scheduled delivery cycle facing delays and customer is waiting, coping up with late delivery you might have to opt for an expensive distribution channel that may raise your cost, sometimes you have to offer a discount to settle the unwanted delay, etc., All these things can raise a cost to the company.
At the same time, Preventive Maintenance keeps your operations away from unexpected equipment breakdowns. It helps you to keep the operations going on and saves you from all the issues listed above.
Well in place Safety:
Major accidents happen in organizations due to unmaintained machines and machine failures. Preventive maintenance makes sure that all the major equipment failures can be assessed before it happens and repair is done before it causes the issue. With well-maintained machinery chance of accidents become very less and your organization becomes safe to work.
Enhance Life of Assets:
Well-planned predictive maintenance can reduce the number of repairs which can reduce the life of an asset. On-time maintenance can give you a well-performing machine for a longer period and hence you need not change them frequently. Your assets’ average life span increases if you keep them free from faults and provide predictive repairs.
What are the Types of Preventive Maintenance?
Preventive maintenance works with different approaches to implement. It works on either a Time-based approach or a Usage-based approach or sometimes on a combination of both.
Time-based Preventive Maintenance
Many names know Time-based preventative maintenance, the most common of which is “calendar-based” maintenance. Whatever title your department chooses, this technique entails establishing a preventative maintenance schedule for inspecting equipment regularly, particularly those that might have a significant impact on output if they broke down.
Usage-based Preventive Maintenance
Usage-based maintenance, commonly known as “runtime maintenance,” is a maintenance strategy that occurs after a particular amount of asset runtime (such as every “X” number of kilometers, miles, hours, or production cycles).
Preventive maintenance based on usage ensures that equipment continues to function as planned by the manufacturer. Unlike time-based maintenance, which follows a more strict schedule, preventative maintenance is done regularly.
Top 5 Industries who Knocked Down their Business with Preventive Maintenance:
1. Oil and Gas Industry
The oil and gas business, one of the early adopters of predictive maintenance, has a primary focus on minimizing maintenance costs while reducing the risk of environmental disasters. What makes predictive maintenance so successful in this industry is the ability organizations now have to remotely monitor the state of their assets, which reduces inspection costs and gives them enough information to make informed decisions.
2. Food and Beverage Industry
The food and beverage business has various maintenance issues, ranging from complex equipment to rigorous regulatory regulations. Damaged equipment can lead to serious health problems in the future. Not only may it harm an organization’s reputation, but in the worst-case instances, equipment failures might result in food spoilage, which could be mixed with fresh items when sent out to clients. Predictive maintenance takes the stage at this point. It places a strong emphasis on the influence it has on operational efficiency and functional performance.
It can be difficult to follow the most stringent and severe food and beverage laws. However, with adequate monitoring of essential equipment, the chances of something unexpected happening are greatly reduced. Especially when combined with predictive technology.
3. Manufacturing Industry
Downtime can cost a large corporation up to $22k every minute. So, what if your wait time is much longer? You can make an educated guess. The expense of merely servicing machines when they break down is shockingly substantial. It’s difficult to predict how much time and production delays will affect a company, so it’s best to avoid the risk and plan accordingly.
When done using preventive maintenance, a machine’s life is extended by three to five percent on average. These few percentage points can save manufacturers millions of dollars if we’re talking about an enterprise. Furthermore, sensor-assisted maintenance and predictive analytics improve product quality and overall equipment efficacy.
4. IT Industry
Almost every service we use today is dependent on computer hardware, from government agencies and hospitals to data centers that run the financial sector and IT technology that controls navigation and telecommunications. It’s easy to see how a protracted period of a service outage or data loss may result in a massive disaster affecting millions of people. Fortunately, preventative maintenance is available. It keeps things in the place and working all the time with pre-planned maintenance activities.
5. Power and Energy Industry
Maintaining a firm grip on maintenance is the only way to remain on top of the ever-increasing costs when dealing with power plants and the process of generating energy through an operation that centers around so many moving parts. Detecting problems and acting on them ahead of time, as in other industries, reduces the risk of failures or setbacks.
It also protects the company from protracted periods of repair, which can result in significant financial losses and, in some cases, insolvency. One of the advantages of predictive maintenance is that it improves asset efficiency, which is a good bonus for the energy industry because it boosts profitability.
How to Implement Preventive Maintenance Successfully in your Organization?
TeroTAM is one of the best CMMS systems to manage maintenance, operations, safety, and training. At TeroTAM, we also offer live chat, comments, and photo sharing into a single digital maintenance platform. To know how our software can help you implement a Preventive Maintenance system in your organization, contact our experts at firstname.lastname@example.org.
With the growing world, time becomes money. Your business can’t afford even a single minute to be wasted due to the negligence of maintenance tasks. Adopting Preventive Maintenance is wiser and advisable to all the business to stay organized and stay competitive. Sign up now with the TeroTAM CMMS platform and get started today with Preventive Maintenance.