How important is maintenance in the industry? (2023)

Industrial maintenence:I'm sure you've heard that term before. But what is the need for maintenance in the industry and why invest in maintenance activities? In this article, we'll show you the importance of industrial maintenance and explain what you need to know. [Updated 2021]

What is Industrial Maintenance?

Let's start with the core of what Industrial Maintenance is. According to Wikipedia definition, “The technical meaning of maintenance involves functional checks, service, repair or replacement of devices, equipment, machines, building infrastructure and support services required in industrial, commercial and residential installations”.

For asset-intensive industries, industrial maintenance is important to maintain reliable instrument and machinery performance, safety, energy efficiency, regulatory compliance and warranty coverage. Additionally, preventative maintenance can have a significant impact on operating costs rather than reactively addressing a problem when it occurs.

To understand this, let's look at the different concepts of industrial maintenance, as they go beyond "preventive" and "reactive".

What are the types of industrial maintenance?

Planning industrial maintenance in advance is important to maintain both the quality of equipment and the quality of the final product. Today, computer applications exist to help planners and programmers get their work done quickly and efficiently by assigning the appropriate people and resources based on priority level and equipment availability for maintenance work.

A company's maintenance process must conform to company policies, security and regulatory compliance requirements, and asset needs. Most of these requirements can be met with preventive maintenance strategies. As there are several types of industrial maintenance that can be applied, let's level with some definitions.

Types of Preventive or Planned Maintenance

  1. preventive maintenanceis also calledscheduled maintenanceand aims to prevent the occurrence of major failures with a well-defined periodic maintenance plan. The plan consists of scheduled maintenance tasks based on weather or asset usage, such as changing the car's oil every 5,000 miles.

    By performing regular preventive maintenance tasks such as inspections, cleaning, lubrication and minor adjustments, small problems can be detected and corrected before they become major problems and cause costly production downtime.

    Preventive maintenance is most often used for assets that regularly fail based on historical Mean Time Between Failures (MTBF) records. It is also used to replace consumables such as oil.

    The downside to preventative maintenance is that parts can be replaced before they even start to wear out, and there's always a chance of collateral damage when doing the maintenance work itself. That's why predictive maintenance was developed.

  1. predictive maintenance It is considered a type of preventive maintenance and is carried out through constant monitoring of equipment and data collection, using this information to predict and prevent equipment failures.

    Equipment monitoring is done with technologies that capture data on asset conditions, such as infrared thermography, acoustic monitoring, vibration monitoring or oil residue analysis. This makes predictive maintenance a way tomaintenance in condition.
    Lostechnologiesused are considered artificial intelligence (AI) and Industrial Internet of Things (IIoT) devices that (when used with maintenance software) support monitoring, data analysis, and triggering maintenance tasks.

    Companies invest in technology to perform predictive maintenance on critical assets that randomly fail (or are subject to failure due to preventive maintenance). Therefore, predictive maintenance mitigates some of the disadvantages of scheduled preventive maintenance.

    The downside to predictive maintenance is the cost, learning curve, and data integration into standard processes, but it's worth the investment in the right use cases.

  2. proactive maintenancelike predictive maintenance, is a way ofmaintenance in conditionwhere the emphasis is on the root cause of problems to extend machine life. While predictive maintenance looks for symptoms of pending failures, proactive maintenance looks for things like oil viscosity to ensure effective lubrication of moving parts or how to properly load a piece of equipment to prevent a problem.
  3. prescriptive maintenancetakes predictive maintenance a step further by not only identifying the change in condition, but also providing recommendations to resolve the issue. For example, a vibration sensor identifies a problem. Prescriptive technologies recommend that equipment be slowed down to a certain extent to extend production time before the asset fails.
  4. detective maintenanceit is the evaluation of assets that are working and the determination of the root cause of failure when an asset breaks down. It is not conditional maintenance, as the intention is not to look for signs of a possible failure, but to test whether the asset is working correctly. For example, test presumably operational fire extinguishers and smoke detectors to ensure they work. While the preventive maintenance task is to replace the battery in the smoke detector.

    After an asset fails, detection maintenance is performed to determine the reason and capture information to feed the preventive maintenance program.

  5. Keep running to failureit is a planned and reactive maintenance strategy designed to minimize costs. Organizations can choose a run-to-failure strategy for items such as expendable assets (machines with expendable parts that must be changed rather than repaired), non-critical assets such as tools, long-lived assets, or assets that cannot be repaired. are subject to wear and/or wear. prone to failure under normal operating conditions, also assets that show random failure patterns that cannot be predicted.

Types of reactive or unplanned maintenance

reactive maintenanceIt is done after a crash, failure or crash and aims to correct the problem so that the asset works again. There are several categories of reactive maintenance, some of which are mentioned here:

  1. Corrective maintenanceIt is intended to improve the working conditions of the machine. Runs when a malfunction is detected and the machine does not work properly according to its designated function.
  2. breakdown maintenanceIt is done when your equipment has a fault and is not working. In shutdown maintenance, production is affected.

Why do you need Industrial Maintenance?

You certainly cannot accept the fact that everything can fail and be replaced. The risk to employee safety and the risk of production interruption are sufficient to justify a planned maintenance program. Here are some additional benefits of preventive industrial maintenance:

  • Increased safety by reducing the risk of injury, death, and therefore liability, due to asset failures or failures.
  • avoid expensive lack of time events that can stop production and result in lost business.
  • Extend the useful life of goods and increase their resale value at the end of their useful life.
  • Reduce maintenance costs as repairs can be much more expensive than the cost of preventative maintenance work. The old adage is true,an ounce of prevention is worth a pound of cure.In fact, a key maintenance efficiency The metric is the ratio of planned to unplanned maintenance.
  • Keep assets running to meet schedule and budget commitments.
  • Reduce energy consumption and operating costs.
  • Maintain warranty coverage with detailed service records to demonstrate compliance with recommended maintenance requirements.

After all, what is Industrial Maintenance?

The reality is that it's a combination of all these types of maintenance activities. In fact, an advanced industrial maintenance strategy isReliability Centered Maintenance, where the type of maintenance approach is determined for each asset in order to maximize uptime and optimize costs and resources.

The need for maintenance in the industry is clear, the real question is how to optimize your maintenance approaches to meet your operational objectives. To get started, consider a partner with experience helping companies move forward inmoving forward in your maintenance processes.

How Sigga can help

Here at Sigga, we've been helping asset intensive industries with SAP improve their industrial maintenance programs for 20 years. We provide software solutions for automate routines steps in the maintenance planning and scheduling process, as well as mobile solutions to support end-to-end tasks in maintenance and warehouse management.

At Sigga, our mission is to empower companies to achieve their mobile digital transformation goals by providing best-in-class software technology.

How important is maintenance in the industry? (2)

Read more aboutSigga and our portfolio of solutionsfor asset intensive industries.

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