Published On July 31, 2023 | 5 Min Read
When it comes to asset management and machine life extension, planned maintenance plays a pivotal role. This preventive strategy ensures the longevity and reliability of equipment, buildings, and other assets. What are the 4 phases of planned maintenance? Experts in this field advise focusing on predictive, preventative, risk-based, and corrective maintenance.
Forbes estimates a $300 million annual difference between industrial plants using preventative and predictive maintenance versus those that run machines until they fail. Understanding each phase’s unique purpose and its role in asset longevity can significantly enhance your project results.
Predictive maintenance is a proactive approach. It relies on data analytics and machine learning to project when an equipment failure might occur and even what might cause it. This approach encourages timely maintenance and prevents unexpected machine downtime. Less downtime also leads to better operational efficiency.
Predictive maintenance works by continuously monitoring the condition and performance of assets. The goal is to identify abnormalities or measurements beyond a safe threshold. Advanced tools and technologies, such as AI and the Internet of Things, are often employed in this process. The real-time data collected is then analyzed to forecast equipment failure.
Companies can reduce costs associated with unexpected equipment breakdowns by adopting predictive maintenance. Managers can also use the data to improve asset utilization and extend the lifespan of machinery. Finally, predictive maintenance helps businesses optimize their maintenance resources and facilitates informed decision-making in asset management.
Preventative maintenance is one of the most commonly used maintenance strategies. It focuses on protecting your assets against unexpected breakdowns. Preventative action involves regularly scheduled inspections and repairs. These minimize the chances of major malfunctions and extend the lifespan of machines.
By inspecting equipment during regular intervals, businesses can detect wear and tear before it becomes a major problem. Fixing smaller problems costs less money and takes less time. In addition, performing preventative maintenance can determine if any additional parts need replacing or adjustments.
Some companies tackle preventative maintenance by creating a maintenance schedule. Manuals often provide recommendations for scheduled maintenance. Contractors that provide repair services also recommend specific intervals for preventative maintenance.
Corrective maintenance, as the name suggests, involves identifying and correcting problems and faults within equipment and systems. It usually occurs after a malfunction or breakdown occurs. Quick reactions in these situations are necessary to restore the system to its functional state.
The process begins with a comprehensive diagnostic procedure. This step identifies the precise issue or a series of problems. After diagnosis, professionals can take appropriate measures to restore the asset’s functionality. Sometimes, corrections face delays if the company needs additional parts or in-house employees lack the skills to service an old or rare machine.
Implementing corrective maintenance is crucial for organizations to mitigate the impact of equipment failure. Although it is a reactive maintenance strategy, it contributes to a comprehensive approach when combined with preventive and predictive maintenance.
Risk-based maintenance is an analytical method that evaluates the risk of potential equipment failures and establishes a maintenance strategy accordingly. It considers factors such as environmental issues, machine age, operating conditions, and component design to determine the likelihood of a breakdown.
Once managers have identified the significant risks, businesses can prioritize their asset maintenance activities in accordance with the highest-risk factors. This helps ensure that the most critical equipment is regularly inspected, serviced, and repaired to prevent costly breakdowns or malfunctions.
Risk-based maintenance is a cost-effective strategy because it allows companies to focus on specific components of their operations that pose the greatest threats. This approach also facilitates long-term planning by offering more accurate predictions for when maintenance activities should take place.
Previously, companies handled asset management by using manual inspections and paper checklists. These still play a critical role in many organizations, but companies can streamline the process by leveraging modern technology.
Sensors are a powerful tool for managing the risk-based and predictive phases. They enable companies to continuously monitor equipment and detect potential issues before they become major problems. Connecting sensors to an IoT platform allows businesses to visualize real-time data and effectively prioritize asset maintenance tasks.
Here are some of the many areas organizations can use sensors or trackers for asset management:
Artificial intelligence and machine learning can also improve asset maintenance. These technologies quickly analyze large amounts of data and identify potential risks or patterns that could lead to failure.
By applying AI/ML algorithms, companies can predict when equipment needs servicing or repair. Doing this before the problem arises further reduces downtime and improves operational efficiency. With this goal in mind, managers can also use AI-based solutions to create personalized maintenance plans for each asset.
Companies should invest in an asset management software solution to manage the four phases of planned maintenance. Such tools provide comprehensive visibility and control over assets. Control allows businesses to optimize their maintenance activities and resources.
This software typically comes with various features to facilitate maintenance:
With these tools, businesses can easily identify any issues with their assets. They can then take measures to minimize risks.
DreamzCMMS is a robust computerized asset and maintenance management platform, offering an integrated solution to manage planned maintenance. DreamzCMMS makes it easier for organizations to monitor, control, and optimize their asset performance and life cycle effectively. Centralizing this information also reduces the time going back and forth between multiple systems.
Now that you understand what are the 4 phases of planned maintenance, you can implement tools to address each. With DreamzCMMS, you’re not just reacting to problems but staying a step ahead of them. If you’re ready to optimize your maintenance strategy and improve your operation’s efficiency, give our asset management solution a try. Contact us today to book your free demo.
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