What is Preventive Maintenance? Why is it essential for any organization?
The goal of a successful preventive maintenance program is to establish consistent procedures to improve the performance and safety of equipment on your property. Preventive maintenance is a planned, controlled program of regular checks, adjustments, cleaning, lubrication, selective component replacement, minor repairs, and performance tests and analyses to ensure the highest reliability and performance throughout the life cycle of buildings, systems, and equipment. Preventive maintenance has lost its urgency as roadside maintenance is commonplace.
Facility operation and maintenance cover the wide range of services, competencies, processes, and tools required to ensure that the built environment fulfills the functions for which the plant was designed and built. It includes the daily activities necessary for the building or building and its systems, devices, residents, and users to perform their intended functions. Operation and maintenance are often combined under the common term “O & M,” because plants that are not operating at maximum efficiency need to be serviced, and they are often discussed as one.
The engineering of electromechanics combines processes and procedures from electrical engineering and mechanical engineering. Electromechanics focuses on the interaction of electrical and mechanical systems as a whole and how they interact with each other. In the design of electronic circuits, the moving parts continue to work with the simplest feedback control systems.
Circuits without moving parts appear in a variety of articles, from traffic lights to washing machines. Electromechanical components are those with moving parts, such as mechanical and electrical actuators. Reliable logic can replace electromechanical devices at any point in a system that relies on mechanical movement for proper operation, but mechanical wear can fail.
A common problem with preventive maintenance is that organizations find that they perform too little maintenance because calendar-based maintenance does not consider the health of the equipment. Predictive maintenance is not a good idea for all types of equipment.
Constant wear and tear can lead to equipment failures that impair operating efficiency. The use of equipment up to failure can cost up to 10x more than a regular maintenance program for a building. As you can see, investing in the right maintenance program can increase productivity and help reduce costs in the long run.
By being ahead of the curve in maintenance and repairs, your department can achieve significant cost savings and higher plant reliability. Preventive maintenance means lower energy consumption of your equipment due to higher operational efficiency, which can reduce your electricity bills. It also reduces safety risks for employees and customers and reduces the costly risk of litigation and industrial action.
Preventive maintenance involves systematic inspection of equipment so that potential problems can be identified and corrected to prevent failures before they occur. Accurate preventive maintenance will vary depending on the operation and type of equipment. In practice, a preventive maintenance plan can include things like lubrication, oil changes, adjustment, repairs, inspection, and replacement of parts, as well as partial or complete overhauls according to a schedule.
Preventive maintenance plans are designed and executed by the maintenance team within an organization in the same way that preventive healthcare saves long-term medical costs. Preventive maintenance programs help plant owners avoid downtime by scheduling work to check equipment before outages occur. Preventive maintenance can extend the life of a device or critical assets compared to reactive maintenance, which occurs when equipment issues need to be fixed.
By definition, preventive maintenance (PM) is maintenance performed on a device or asset to reduce the likelihood that it will fail. Reactive maintenance strategies, also known as a glitch or corrective maintenance, are the process of repairing equipment after it has failed. It can lead to excessive downtime and repair costs and unplanned downtime, so it is recommended to approach 10% of your assets.
Reactive maintenance is cost-effective when performed on equipment with minimal repair costs, but it can damage production and your business. Both unplanned and reactive maintenance have many overheads that can be avoided through the planning process. Unplanned maintenance can cost three to nine times more than scheduled maintenance.
The cost of unplanned maintenance includes production outages, higher prices for parts and shipments, lost time in responding to emergencies, and diagnosing failures when equipment is not working correctly. For certain systems, such as a hotel air conditioner in the height of summer, unplanned downtimes can lead to a loss in sales.
There is nothing worse than having a critical equipment breakdown when it is needed. Throughout the life cycle of critical equipment, technical and maintenance personnel carry out condition monitoring and inspections. Preventive management is more complex for companies with a lot of equipment.
This time-based approach has a variety of names, but the most important is calendar-based maintenance. Compared to condition monitoring maintenance, time-based maintenance does not require a specific monitoring strategy and makes it superfluous to interpret actual condition data and act accordingly. Equipment can be continuously processed and inspected, and personnel can focus on proactive or reactive maintenance tasks.
Predictive maintenance reduces the likelihood of replacing parts, as opposed to regular maintenance. Maintenance plans are planned and communicated in advance so that maintenance activities have little impact on the productivity and efficiency of the company. As mentioned above, maintenance should be done regularly, not just with a time-based strategy.
With an effective preventive maintenance program, organizations see improvements in their business processes and costs, including improved productivity, reduced waste, improved workflow, and fewer unexpected downtime. Smaller problems are solved more quickly and do not incur expensive repair, downtime, and replacement costs. Coordinating scheduled and unplanned maintenance reduces unscheduled downtime and improves response times to problems and system failures.
Preventive maintenance is like other reactive maintenance, a relatively simple maintenance strategy that needs to be implemented and implemented but requires following manufacturer recommendations and developing static maintenance plans for critical equipment. Condition monitoring can be carried out using various techniques and requires the plants to transmit their actual status to your maintenance management system in real-time.
Repair costs include labor and material costs, additional working hours, and direct and indirect maintenance costs. The total failure and standstill of plants, plants, and entire plants can indicate the degree of effectiveness of a PM program.
In cases where equipment can be repaired and replaced cheaply, production delays, safety issues, reputational damage, and employee dissatisfaction are enough reasons to look for ways to reduce the number of unexpected machine failures. Preventive maintenance is increasingly used in heavy industry, manufacturing, aviation, and construction, but can also be used in industrial maintenance and facility management.