Usage based maintenance (UBM) is reshaping preventive maintenance strategies in industries all over the world. Because technology is allowing facility managers to see the performance of their equipment in real-time, they can increase the precision of maintenance work.
UBM is an alternative to some of the more traditional ways of proactively scheduling maintenance. When organizations service machinery based on actual usage, they use their resources more wisely, experience less downtime, and extend asset lifespan and performance. If you’re striving for operational excellence in your business, mastering UBM is essential for effective asset management and navigating today’s complex, technology-driven maintenance landscape.
What is usage-based maintenance?
Usage-based maintenance (UBM) is a preventative maintenance strategy that triggers maintenance activity based on how much an asset has actually used since its last upkeep, rather than pre-determined time intervals or calendar-based triggers. To achieve UBM, your maintenance plan will rely on key attributes and data such as:
- Operating hours
- Production cycles
- Mileage
- Energy consumption
UBM adapts to conditions that actually occur on your factory floor. This is different than traditional planned maintenance or time-based maintenance that follows predetermined schedules you set regardless of how much your equipment gets used. UBM differs from condition based maintenance (CBM), in which maintenance teams take action based on the health of equipment, which is often determined based on sensors, meters, or other condition monitoring devices.
UBM prevents maintenance teams from being either too cautious or too active. Workers can perform maintenance activities when they’re truly needed instead of intervening prematurely or taking too long and running into unexpected breakdowns. Not every piece of equipment is used the same way or at the same rate, and UBM lets you tailor your maintenance strategy for each item and better manage your team’s workload.
How usage-based maintenance works
Collecting data and analyzing key metrics on a continuous basis is the foundation of UBM, paving the way for predictive maintenance. The process begins with establishing usage thresholds for each piece of equipment, which is often derived from manufacturer recommendations or performance and maintenance history. Also, technology that facilitates maintenance triggers is key to implementing effective UBM:
- Internet of Things (IoT) sensors monitor equipment usage in real time
- Computerized Maintenance Management Systems (CMMS) track and analyze collected data
- Automated systems generate work orders when thresholds are reached
As equipment approaches its predetermined usage limit, the maintenance management system triggers notifications to the maintenance team. This proactive and streamlined approach lets technicians schedule and prepare for the maintenance tasks to come, which makes disruptions to operations less likely.
As for CMMS, this maintenance software is generally the hub of all your activity, taking data from various sources and giving you a view of the overall state of your equipment. With it you can:
- Visualize usage trends
- Adjust thresholds and maintenance triggers as needed
- Use maintenance history to forecast the tools and parts needed for upcoming maintenance
- Generate reports in order make more informed decisions
These tools can help your team create a dynamic workflow that more efficiently responds to actual equipment needs, rather than servicing equipment based on an arbitrary timeframe or blind schedule.
Benefits of usage-based maintenance
Usage based maintenance offers numerous advantages that help you go beyond simple reactive maintenance, and can significantly improve your bottom line and operational efficiency.
1. Cost savings
By performing maintenance only when specific machinery needs it, UBM reduces the risk of unexpected equipment failure and unplanned downtime, while also avoiding expenses related to unnecessary parts replacement or maintenance costs involved with performing too much labor. This targeted approach often leads to fewer maintenance expenses overall and better resource allocation.
2. Improved regulatory compliance
Industry regulations are always evolving, but UBM helps organizations stay ahead of it by providing detailed usage and maintenance records. This makes audits easier and reduces insurance premiums. It also shows you’ve been dutiful in maintaining the integrity of the equipment over time, reducing risk of accidents or legal issues.
3. Tailored performance
UBM helps you fine tune the performance of an individual piece of equipment based on its characteristics and how it is used. Consider factors like environmental conditions, operator expertise, or how often you need to use the machinery, and then make changes to settings or frequency of maintenance. By adapting to each asset’s unique circumstances, UBM enhances the quality of the product you put out, helping you produce more of it with greater consistency.
4. Enhanced sustainability practices
UBM contributes to environmental sustainability by optimizing resources. When you perform maintenance only when necessary, the organization consumes fewer unnecessary parts, minimizes waste from replacing items prematurely, and lowers energy consumption associated with excessive maintenance.
5. Improved equipment performance
Every maintenance cycle turns into a learning opportunity. As maintenance technicians gather more data, you’ll find ways to tweak how your equipment runs, often discovering new capabilities you didn’t know existed. This ongoing process helps your assets perform better and last longer than you might have expected.
Steps for setting up usage-based maintenance
Making the leap to a UBM program involves several stages and each is important if you want to get the job done right. Here’s a roadmap to guide your organization through the process:
- Assess whether you’re ready: How are you currently evaluating your equipment? Are there any gaps in your routine maintenance and data collection capabilities? Figure out which assets are the prime candidates for UBM based on how important they are to your operations or their usage patterns.
- Develop a pilot program: Select a small number of items for UBM implementation. These case studies let you test and refine processes before using them on a wider scale in your preventive maintenance program.
- Set up unique ways to see how each machine is used: For instance, with an air compressor, count how many times it turns on and off. For a truck, track both how many miles it’s driven and how many hours the engine has been on. This gives you a more accurate picture of the wear and tear for each asset.
- Create flexible maintenance protocols: Streamline maintenance procedures based on usage. For example, you can assign a more experienced technician for certain scenarios, or do a lighter, quicker checkup for equipment that needs less upkeep.
- Use feedback to continually refine your approach: Set up regular review meetings with operators, technicians, and managers to gather insights on the UBM program’s effectiveness.
Embracing the Future of Maintenance
UBM is changing preventive maintenance plans in many industries, making organizations smarter and more efficient. As technology advances, UBM will become an important stepping stone to leveraging tools like AI, helping teams improve the precision of their maintenance programs. Companies adopting UBM are positioned as future leaders in and will inevitably have an edge in the marketplace.
Schedule a free demo today to learn more about implementing UBM backed by modern maintenance management technology.
