Industrial maintenance and programs maintenance is critical to a company's productivity and reliability. As a result, several different forms of maintenance coexist to allow manufacturers to optimize their manufacturing processes. Each business determines its industrial maintenance requirements and develops a strategy to meet them.
As a maintenance technician, or the maintenance engineer, you'll be responsible for a variety of appliances and systems, and you'll use a variety of tactics and ways to do so. Understanding the many types of maintenance procedures, as well as how and when they are utilized, is essential for success in the maintenance sector.
Types of Maintenance
Organizations employ several forms of maintenance to enhance the uptime of their assets and the usability of their facilities. One or more maintenance types are utilized depending on an organization's budget, resources, combined experience, and maintenance goals.
Predictive maintenance, for example, will be used at a manufacturing plant that has a staff devoted to maintenance technology and is controlled by a multibillion-dollar corporation. Reactive maintenance is used by a small facility that is operated by a private firm and is just starting to bring maintenance in-house. However, when the firm realizes the high costs of reactivity, it will begin experimenting with proactive maintenance methods.
It's unusual for a company to employ only one form of maintenance. Even a cutting-edge manufacturing facility with predictive maintenance technologies will utilize less sophisticated maintenance methods. Because not all assets are created equal, this is the case. A $100,000 essential equipment will have conditional monitoring sensors added for predictive maintenance, whereas a $5,000 non-critical item will get preventive or breakdown repair.
To figure out which sorts of maintenance to use, you must first figure out the ones you're already doing and what your maintenance goals are. You must also be aware of your financial and resource constraints. Maintenance workers and maintenance software are required for successful deployment, even if you are transitioning from a maintenance approach to a reactive strategy.
What are the Different Types of Maintenance?
Here is an overview of the most frequent forms of maintenance :
- Preventive Maintenance.
- Corrective Maintenance.
- Condition-Based Maintenance.
- Predictive Maintenance.
- Predetermined Maintenance.
- Scheduled maintenance.
- Planned maintenance.
- Routine maintenance.
- Deferred maintenance.
- Total productive maintenance.
Let's look at these concepts more closely to have a better grasp of them!
1.Preventive Maintenance
Preventive maintenance is to detect and correct problems before they occur. It's most often done in the form of routine inspections, which happen many times a year.
When inspecting a system or piece of technology, look for any symptoms of wear, tear, or impending failure. Replace any broken parts as soon as possible. If anything unexpectedly fails, you won't have to go into "crisis mode."
The major advantage of preventative maintenance is that it may help you avoid unplanned downtime by catching problems early on.
2.Corrective Maintenance
When an issue is found while working on another work order, corrective maintenance is started. Issues are caught ‘just in time' with remedial maintenance.
For example, a maintenance worker may detect that a pipe in an HVAC system is not functioning properly during a routine maintenance check or when repairing another issue. The issue is then fixed or replaced at a later period during corrective maintenance.
It lowers emergency repairs and enhances employee safety since corrective maintenance concerns are discovered "just in time."
3.Condition-Based Maintenance
Condition-based maintenance is often thought of as a more advanced kind of preventative maintenance. Machines and systems are carefully watched for changes that might suggest imminent failure rather than being inspected on a timetable.
Condition-based maintenance involves specialists watching the system operate and identifying variables that might impact its performance, such as temperature, vibration speed, power, moisture presence or absence, and so on.
4.Predictive Maintenance
Predictive maintenance is a form of condition-based maintenance in which systems are monitored continuously using sensor devices. These devices are connected to system components and provide software with continuous, real-time data. This data is then interpreted by the program, which alerts maintenance workers to impending risk.
Predictive maintenance is often regarded as the most advanced and time-consuming kind of maintenance. This is due to the large amount of data to analyze and the sensor devices themselves needing to be maintained and examined on a regular basis.
5.Predetermined Maintenance
Predetermined maintenance, unlike other methods, is carried out using guidelines and suggestions devised by the original manufacturer rather than by the maintenance staff. These ideas are based on data obtained through trials.
Typically, when the equipment is originally acquired, the manufacturer gives statistics and guidelines, which will include data on the average lifespan of both the overall system and its different elements. The manufacturer will advise you on how frequently you should examine, maintain, and replace parts.
Because technicians may not be able to predict issues, relying entirely on a preset timetable may result in system failure. It can also lead to multifamily maintenance staff replacing parts too soon, leading in extra expenses. Furthermore, because the program is based on statistics rather than the actual status of the equipment, scheduled maintenance does not ensure that a system will not break down.
6.Scheduled maintenance
Work that is planned for completion on a calendar is referred to as scheduled maintenance. Calendar-based preventative maintenance activities are the most frequent form of planned maintenance. These are planned far in ahead of the project's completion. In a given year, an asset with a monthly PM, for example, will have twelve instances of planned maintenance. However, just because maintenance is scheduled does not always imply that it is intended. Parts, supplies, expertise, and other resources must all be accessible throughout the designated time window, according to a maintenance planner or other sort of maintenance worker.
7.Planned maintenance
Maintenance that is planned ahead of time is referred to as planned maintenance. It's also the most often monitored key performance indicator (KPI). A high planned maintenance percentage implies that a maintenance team will have the resources necessary to accomplish work on the specified day and time. Other maintenance KPIs, such as schedule compliance, benefit from having a high scheduled maintenance percentage. More planned maintenance equates to more effective scheduled maintenance completion.
8.Routine maintenance
Although some companies discriminate between routine maintenance and preventive maintenance, routine maintenance is a type of time-based maintenance and preventative maintenance. They utilize the latter for smaller activities (such as cleaning) that occur more frequently (hourly, daily) and the former for bigger duties (such as inspections) that occur less frequently (weekly, monthly, annually). Operators, janitors, and other members of the staff do normal maintenance, while technicians perform preventative maintenance. Non-routine maintenance refers to work that is done in response to an asset's condition or just when it is required.
9.Deferred maintenance
Deferred maintenance refers to repairs and inspections that have been put on hold owing to a lack of funds and resources. While delaying maintenance saves money in the short term, the costs of not conducting critical maintenance grow at a rate of 7% each year. Fines arising from failed inspections and unexpected downtime that halts operations are driving up expenses. Deferred maintenance and emergency maintenance are the two forms of maintenance that are least desired.
9.Total productive maintenance
Total productive maintenance (TPM) is the widest form of maintenance, encompassing more than just the assets that need to be kept in good working order. It also tries to boost employee morale and happiness in the workplace, particularly in industrial companies. TPM does this by boosting overall equipment effectiveness (OEE) and reducing scheduled maintenance. More scheduled work implies more people have the resources they need to complete their tasks, resulting in better job satisfaction. TPM also encourages machine operators to take an active role in maintenance and ownership of their machines.
💡 Tip
Regardless of the maintenance strategies employed by your team, certain parts of must be maintained on a regular basis to avoid costly repairs or lengthy downtime. Similarly, in order to avoid falling behind, your maintenance professionals' knowledge and abilities must be continuously maintained and updated.
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