Top 5 Most Important Types of Preventive Maintenance in Manufacturing

September 6, 2022

Equipment is the backbone of all manufacturing companies, and keeping facilities running smoothly is crucial to producing quality goods. Wear and tear is inevitable, but if machines are down due to a lack of routine upkeep, you’re going to run into some very unhappy customers (and employees). Preventive maintenance tackles small repairs so minor issues don’t become major problems later on.

People don’t get health or car insurance after they get sick or their vehicle breaks down. Having coverage and a plan in place before incidents occur adds a layer of protection for the future. Likewise, scheduling maintenance on your equipment and coming up with a set schedule will benefit your facilities not just down the road, but frequently throughout the lifecycle of your equipment. 

Using equipment inventory management software to track work orders and schedule preventive maintenance tasks will keep your well-oiled machine operating with maximum efficiency.

preventive maintenance examples for your maintenance team include time based preventive maintenance

5 Types of Preventive Maintenance for Manufacturing Facilities

There’s no way to avoid all emergencies or unforeseen problems in a facility, but having a plan in place to perform maintenance tasks on an ongoing basis has numerous benefits. There are multiple types of preventive maintenance you can implement within your plant or factory.

Consider starting with the following:

  1. Time-Based
    Schedule maintenance tasks ahead of time at regular intervals, such as daily, weekly, or monthly. Use preventive maintenance software that includes a calendar and planning tools to review ongoing task scheduling routines and make changes easily to minimize unproductive time.

  2. Usage-Based
    When a piece of equipment has been used a certain amount of times, plan to replace parts before they become worn out and break. How many uses each machine should be limited to will depend on many factors, such as age, repair history and so on. Use asset tracking software to inform how often to maintain each piece of equipment based on usage.

    preventative maintenance measures are streamlined with a preventive maintenance software

  3. Condition-Based
    This type of preventive maintenance requires frequent quality inspections of your equipment. When a machine’s quality dips below a certain pre-determined threshold, you can address it. Think about this like charging a cell phone when the battery falls to 10 percent capacity, rather than waiting until the device dies every time.

  4. Predictive
    Often, the term ‘predictive maintenance’ is used interchangeably with preventive maintenance. It’s impossible to predict exactly what will happen in the future, but logging and reviewing historical data will help you determine what maintenance tasks should be assigned and when they should be implemented. Artificial intelligence within certain equipment inventory management software can help you predict, plan and schedule repairs.

  5. Ongoing
    Over-maintaining machinery can be expensive and unnecessary, so determine which maintenance tasks truly need to be performed regularly. Regular inspections can help prevent minor wear from turning into larger repairs or replacements later on. 

    Your preventive maintenance plan should include a preventive maintenance software that can track maintenance costs

Advantages to Setting a Preventive Maintenance Schedule

Preventive maintenance involves careful planning of actions needed to maintain the lifecycle of equipment used in manufacturing and production. This type of scheduling is used to identify problems before they occur, with the added benefit of having a system in place to remedy them.

Reduced Equipment Downtime

Research shows large manufacturing facilities lose an average of 27 hours a month to machine failures, costing $532,000 per hour of unplanned equipment downtime. Reactive maintenance can slow down the entire production line, while planned or preventive maintenance will minimize unproductive time. Reliable equipment that is regularly inspected will lead to fewer breakdowns and time spent on major repairs.

preventive maintenance programs emphasize preventive maintenance task tracking as part of your maintenance strategy

Planning for Labor and Resource Costs

Repairs and breakdowns cost maintenance companies time and money. Broken machines can mean hiring outside labor or paying employees overtime if they have to pivot and fix a machine to do their regular jobs. Carrying out simpler, less involved tasks on a regular basis helps prevent system failures or breakdowns. 

Staying on Top of your Facilities so they’re Operating Smoothly

Machinery isn’t the only thing that needs general maintenance and upkeep in a manufacturing plant or factory. Preventive maintenance can include light servicing or cleaning at the end of each work day, and keeping the entire facility tidy and in good working order. An orderly, well-maintained working environment will help keep production lines and equipment moving steadily.

routine maintenance is a daily part of maintenance operations highlighting the need for a preventive maintenance strategy

Preventing Product Defects

When manufacturing equipment breaks, production can stall or grind to a halt. Another aspect to consider is that faulty equipment can produce low-quality or substandard products. Using a system for preventive maintenance helps you quickly determine what machines are becoming inefficient or in need of upgrades early on to ensure all goods are manufactured to standards.

Keeping Employees Safe

Safety is a crucial reason you should have an effective preventive maintenance plan for your facility. Maintaining equipment properly can lead to a safer workplace, and regular inspections of fire prevention materials, exit lights and any potential hazards on the floor should be part of your routine operations. 

Streamline Preventive Maintenance Tasks for Your Facility

With a plan and the right tools in place, costs of replacement or emergency repairs can be anticipated and even reduced with preventive maintenance. 

Manufacturing facilities can use a computerized maintenance management system (CMMS) to organize and delegate preventive maintenance tasks that will save you time and money in the long run.

See how Maintenance Care can help by booking a demo today.