Preventive maintenance in manufacturing: what it is, types, advantages and benefits (2023)

Industrial machines are at the heart of companies that produce in large quantities. Just as we take care of our bodies with preventive health measures, the equipment used to manufacture all kinds of goods also needs special prior attention to avoid damage and wear over time.

Preventive maintenance in manufacturing is a measure aimed at keeping machines in good working order so that they can run at 100% efficiency. This saves maintenance costs due to unexpected breakdowns and downtime that can occur and have a significant impact on a company's bottom line.

(Video) What is Preventive Maintenance?

This type of preventive maintenance in the plant guarantees the correct operation and performance of industrial machines. What is it made of? What types of maintenance are there? How and why is this action performed?

What is preventive maintenance?

Preventive plant maintenance is a series of actions that are carried out in an integral and systematic way to guarantee that the operation of a machine is carried out in perfect conditions. That means no hiccups or failures that could lead to major production failures in the future.

It consists, among other things, in the timely verification of the components in terms of safety, calibration, mechanical and electrical. These are the things that guarantee that a given machine will work efficiently and effectively and that the expected results will be achieved. There wouldn't be much point in installing some kind of conveyor if we don't do the necessary preventative maintenance later. Otherwise, higher costs would be incurred if these parts suffered significant wear.

This type of maintenance is usually carried out under certain parameters and protocols that are established in a specific plan previously prepared. The goal of such a preventive maintenance program in manufacturing is to prevent serious damage to production machinery in the future.

Types of preventive maintenance in manufacturing.

  • Preventive maintenance scheduled by time

When periodically reviewing a component that presents a condition with risk of failure, which would permanently affect the production process in case of deterioration.

  • Usage-based planned preventive maintenance

It consists of carrying out the assessment or verification of a part that has been in use for a long time and after a certain time needs maintenance. This happens before it has a chance to crash. Therefore, the inspection is carried out to avoid unexpected failure.

  • non-disruptive maintenance

It is a type of preventive maintenance in manufacturing that is carried out when the machine is running. This maintenance guarantees that the production process of the plant is not interrupted.

  • Predictive Maintenance

It is performed when the estimated useful life of the component or device has expired.

(Video) What is Predictive Maintenance? | Working, Advantages, Disadvantages of Predictive Maintenance

  • Scheduled maintenance

Planned maintenance is carried out according to the times and measures established in hours or kilometers of operation of the machine.

  • passive maintenance

It is a type of maintenance carried out with the aim of installing a safety barrier so that the machine can work in optimal conditions without its operation being affected by external factors such as bad weather and work accidents.

  • active maintenance

It consists of the constant monitoring of the operation and wear of the machine components. This is done to ensure that everything works correctly and there is no risk of fatal errors.

All of these types of preventive maintenance in manufacturing are beneficial in keeping the machine running smoothly, efficiently, and at all stages of the production process. The operation of the machines will continue until the planned objectives are achieved.

Why do preventive maintenance on industrial machinery?

It can be assumed that devices tend to wear out with use or operation until they eventually break down. The objective of preventive maintenance in production is precisely to avoid irreparable damage that can lead to the total failure of the machine.

Well-planned preventive maintenance prevents machine problems during the production process by performing tasks such as cleaning, lubrication, component adjustment, or part replacement. Its efficient use is optimized.

The records made at each stage of this type of maintenance allow technicians and operators to determine the state of the machine.

How to perform preventive maintenance in manufacturing?

Good planning is the starting point for quality preventive maintenance. It is also necessary to implement tools that facilitate the development of each process in an optimal way, to avoid having to take corrective actions.

(Video) What are the benefits of preventive maintenance?

The first thing to do is take an inventory of everything that needs to be included in maintenance. Second, it's important to set a budget and start with the initial review, considering whether any legwork has already been done or if you're starting from scratch.

When performing preventative maintenance, it is important to have the machine manufacturer's manual and any other necessary information on hand.

Another task is to define the type of maintenance and delegate the responsibilities to the appropriate worker or workers so that they are carried out efficiently during the execution of the plan with adequate control and supervision.

It is necessary to implement an automated process that allows the recording of all activities and inputs used during the inspection, detection, correction and prevention phases of the maintenance carried out.

How to implement a preventive maintenance plan?

One of the most effective ways to develop an optimal preventive maintenance plan is to use computer software that automates tasks and all processes.

These programs give you instant and secure access to all the equipment and components involved in the maintenance process, as well as instant information at every stage of the operation.

A well formulated preventive maintenance plan guarantees a better organization. Using software, you can create an asset mapping to inspect equipment when needed through a scheduling module that executes work orders.

Seven benefits and advantages of preventive maintenance in manufacturing

Carrying out a calendar of preventive measures in industrial machinery has numerous advantages.

(Video) Advantages and Disadvantages of Preventive Maintenance

Here we summarize the most important ones:

  • Guarantees knowledge of the status of each machine and its components.
  • Avoid unexpected downtime by quickly detecting failures.
  • It guarantees the occupational safety of the operator and his entire environment.
  • It guarantees the perfect operation of the machine in the long term.
  • Reduce unforeseen work stoppages.
  • Reduces expenses and corrective maintenance costs due to subsequent breakdowns.
  • Creates longer machine life and higher overall production levels.

How often should maintenance be performed?

For correct industrial maintenance it is advisable to have a long-term vision and plan well in advance. The special characteristics of the respective industry must be taken into account.

For example, if a company has an automated production system, scheduled maintenance and overhaul of the machines becomes easier and faster.

In addition, if a company has processes with seasonal production peaks, it is always recommended to carry out preventive maintenance at the beginning of the season to avoid problems during the busiest months.

During the summer, it is common for some industries, such as the chemical, electrical, automotive, food, etc., to suffer productive and technical stops. In addition, a high percentage of the workforce is on vacation and activity is declining. It is normal to spend time on maintenance and other tasks such as improvements, extensions or new installations. The summer months are an excellent time to review and update a company's processes.

On the other hand, there are businesses that do not close in summer. In this environment, high ambient temperatures force many machines to work at their limits. It is vital that any equipment that is at risk of failure is properly maintained and cleaned.

Finally, the internal and legal regulations applicable to each type of production plant determine the frequency of both maintenance and mandatory inspections related to preventive maintenance in production.

FAQs

What is preventive maintenance and its types? ›

Preventive maintenance (PM) is the regular and routine maintenance of equipment and assets in order to keep them running and prevent any costly unplanned downtime from unexpected equipment failure. A successful maintenance strategy requires planning and scheduling maintenance of equipment before a problem occurs.

What is preventive maintenance and advantages? ›

Performing preventive maintenance prolongs the life of your equipment, reduces downtime, decreases reactive maintenance requests, helps you manage compliance and inspection needs, and prevents costly emergency repairs from occurring.

What are the 4 types of maintenance? ›

4 types of maintenance strategy, which one to chose?
  • Corrective maintenance.
  • Preventive maintenance.
  • Risk-based maintenance.
  • Condition-based maintenance.

What are the types of preventive? ›

  • There are 4 major types of preventive maintenance. ...
  • Usage-based preventive maintenance. ...
  • Calendar/time-based preventive maintenance. ...
  • Predictive maintenance. ...
  • Prescriptive maintenance.

What are the 5 preventive maintenance? ›

Protect and enhance the value of your assets with Iota's Internet of Things solutions. Talk to us about how to get started today.
  • Time-based Maintenance (TBM) ...
  • Failure-finding Maintenance. ...
  • Risk-based Maintenance. ...
  • Condition-based Monitoring (CBM) ...
  • Predictive Maintenance.
21 Mar 2019

What is the benefit of maintenance? ›

Improves equipment efficiency

Preventive maintenance provides the equipment with regular maintenance, lubrication, cleaning, and inspections that help it run more efficiently and identify any problems that might not be visible on the surface.

What are the 4 steps of preventive maintenance? ›

There are five main steps involved in creating a preventive maintenance schedule. Let's take a look.
...
Let's take a look.
  • Take inventory of your assets. ...
  • Prioritize your assets. ...
  • Determine ideal preventive maintenance intervals. ...
  • Schedule recurring maintenance tasks.
22 Jun 2020

What are the 3 types of preventive maintenance? ›

There are three main types of preventive maintenance: Time, usage, and condition-based triggers. A variation of these types of preventive maintenance should ideally be scheduled and performed on all equipment items to prevent unplanned failure.

What are the 8 preventive maintenance? ›

They are purchasing, operator training, technician training, scheduled maintenance, repairs, consumables, fleet sizing and machine disposal. Bundle them all together and you have a total package that will increase the machine's life cycle and, at the same time, maximize the unit's economical value.

What are the 3 main types of maintenance? ›

The Three Types of Maintenance
  • Corrective Maintenance.
  • Preventative Maintenance.
  • Predictive Maintenance.
15 May 2015

What are the two 20 general types of maintenance? ›

What are the maintenance strategies?
  • Reactive (run-to-failure)
  • Predetermined maintenance.
  • Preventive maintenance.
  • Corrective maintenance.
  • Condition-based maintenance.
  • Predictive maintenance.
21 Jun 2021

What are the 4 types of maintenance PDF? ›

Types of Maintenance (Definitions, Benefits, Cost, Examples)
  • Preventive Maintenance.
  • Predictive Maintenance.
  • Planned Maintenance.
  • Condition-Based Maintenance.
19 Aug 2020

Why preventive maintenance is important? ›

A preventive maintenance program is an important part of successful facility management. It keeps equipment operating efficiently, increases the safety of your employees, and helps you avoid large and costly repairs down the road.

What is preventive maintenance PDF? ›

Preventive Maintenance involves proper planning to prevent equipment failure, Hence it is complex. Normally more expensive as equipment already failed and need replacement or extensive repairs. It prevents equipment failure and normally less expensive. Loss of production and time due to asset failure.

What is preventive and example? ›

intended to stop something before it happens: In the past ten years, preventive measures have radically reduced levels of tooth decay in children. preventative medicine. More examples.

What preventative means? ›

pre·​ven·​ta·​tive pri-ˈven-tə-tiv. : devoted to or concerned with preventing something from happening : preventive entry 1. The best preventative medicine that you can give to your plants is to mulch them.

What is the best type of maintenance? ›

Preventive maintenance is probably the most popular maintenance management strategy…at least it gets the most buzz in the industry. When the quality of production is impacted due to unreliable equipment and costs skyrocket because of unplanned servicing, it's probably time to consider a preventive maintenance program.

What are 8 pillars of TPM? ›

What are the 8 Pillars of Total Productive Maintenance?
  • Focused Improvement.
  • Autonomy.
  • Quality Maintenance.
  • Planned Maintenance.
  • Early Equipment Maintenance.
  • Training and Education.
  • Safety, Health and Environment.
  • Office TPM.

What is PM and CM in maintenance? ›

Difference between CM and PM : Corrective Maintenance. Preventive Maintenance. CM is performed after asset failure or after anything goes wrong. PM is performed before asset failure or before anything goes wrong.

What is preventive maintenance tool? ›

Preventive maintenance is concerned with increasing the usability and longevity of manufacturing equipment. An optimized preventive maintenance (PM) must take into account every step of the process from quality work instructions down to work execution and reporting.

What are the 3 important steps in performing preventive maintenance? ›

3 Simple Steps to a Preventative Maintenance Schedule
  • Step one: Take an inventory.
  • Step two: Get your assets ready for maintenance.
  • Step three: Do it.
  • Getting started with the right software.
11 Dec 2017

What are the 2 kind basic preventive maintenance? ›

There are two main types of preventive maintenance: calendar-based maintenance, and usage-based maintenance.

What is preventive maintenance PPT? ›

It is a planned maintenance of the plant and equipment's which is designed to improve equipment life and avoid any sudden failure. It includes painting, lubrication, cleaning, adjusting and component replacement to prolong the useful life of the production equipment. Read more. Technology.

What is preventive maintenance examples? ›

For example: performing regular business and equipment inspections, cleaning and lubricating essential equipment, and tidying your business's grounds are all examples of preventive maintenance. The goal of preventive maintenance is to prevent equipment failure before it occurs, and to reduce the risk of accidents.

What is PM schedule? ›

What Is a Preventive Maintenance Schedule? A preventive maintenance schedule is a plan for organizing company resources to ensure maintenance tasks are performed according to specific time or usage triggers. The primary goal of preventive maintenance is to keep assets in optimal working condition.

What are the types of maintenance method? ›

What Are the Different Types of Maintenance? The 6 different types are; Predetermined Maintenance, Preventive Maintenance, Corrective Maintenance, Condition-based Maintenance, Predictive Maintenance and Reactive Maintenance.

What are the 4 types of maintenance PPT? ›

maintenance,types of maintenance,Breakdown maintenance,preventive maintenance,predictive maintenance & schedule maintenance - PowerPoint PPT Presentation.

What are the benefits of maintenance? ›

Top five benefits of maintenance management
  • Reduces equipment failure and unplanned downtime. This is one of the top reasons why organizations focus on maintenance management. ...
  • Extends equipment's longevity. ...
  • Helps with workplace safety. ...
  • Helps keep costs under control. ...
  • Improves equipment efficiency.
21 Jan 2022

What is the function of preventive maintenance? ›

Preventive maintenance, or PM, is regular, planned maintenance that is scheduled according to usage or time-based triggers. The purpose of PM is to lessen the likelihood of equipment breakdowns.

What are 2 kinds of basic preventive maintenance? ›

There are two main types of preventive maintenance: calendar-based maintenance, and usage-based maintenance.

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