A preventative maintenance program is crucial for an asset management program to be successful. A preventative maintenance program decreases the extent of reactive maintenance to a level low enough that the other initiatives in the asset management process can be effective.
In preventive maintenance, assets are repaired and serviced before failures occur. The level of maintenance is determined by schedules generated from the CMMS system. Preventive maintenance performed at regular intervals will usually result in reduced failure rates with the aim to eliminate unnecessary inspection and maintenance tasks. This type of maintenance, although it is still quite widespread, entails a considerable increase in plant management costs and the impact of scheduled downtime, therefore requires good planning.
The higher the consequence of failure is to the business, the greater the level of preventive maintenance that is needed. This ultimately implies a trade off between the cost of performing preventive maintenance and the cost to run the equipment to failure.
Effective preventative maintenance activities would enable a company to achieve a ratio of 80% or more proactive maintenance to 20% or less reactive maintenance. Reactive maintenance typically costs 2 to 4 times what proactive maintenance costs, due to its inherent inefficiencies. Where we can help you:
Typical project benefits, achievable within Preventative Maintenance:
- Defining the proper level of maintenance, through optimisation of the maintenance/output ratio
- Financial optimisation of costs versus output
- Defining the procedures of programming and performance of intervention
- Planning and optimisation of resources for maintenance
- Lowers overall maintenance costs through better use of labour and materials
- Increases equipment availability
- Reduces the size and scale of repairs
- Reduces investment by not needing spare or stand by units
- Increases equipment’s useful life
- Reduces number of repairs
- Reduces downtime