When it comes to effective equipment, machinery, and facility upkeep in 2021, companies simply can’t afford to ignore the important benefits of preventive maintenance.
Equipment failures and emergency repairs can be very expensive in this day and age.
If maintenance costs and equipment downtime are major asset management considerations for a company, it needs to include preventive maintenance activities in its maintenance strategies.
However, recently we’ve seen newer entities preferring reactive maintenance plans instead. This is due to both a lack of knowledge of how beneficial a preventive maintenance program can be.
In case you’re wondering which form of upkeep will best suit your company, read on. In this article, I’ll list six of the biggest benefits of preventive maintenance for companies in 2021.
Let’s get started.
What is Preventive Maintenance? [An Overview]
Basically, preventative maintenance is a group of activities that maintenance personnel performs on machinery, facilities, or various equipment to prevent them from malfunctioning or otherwise requiring major repairs.
It’s related to predictive maintenance in the way that it’s meant to prevent unplanned downtime and keep critical parts from being damaged beyond repair.
A preventative maintenance program includes a variety of maintenance tasks geared towards making sure there are no hidden faults or cracks that could cause equipment breakdowns.
Any piece of equipment (industrial, commercial, etc.) needs regular maintenance to keep it in optimal working condition.
‘Preventive’ is the only type of maintenance that makes sure companies achieve that with maximum cost-savings.
6 Benefits of Preventive Maintenance for 2021
If continuous improvement in uptime and equipment life is one of the KPIs at your company, it can benefit from a preventive maintenance schedule.
Here are the six most prominent benefits of preventative maintenance for companies looking to avoid unplanned maintenance and malfunctions in 2021.
Lower Maintenance Costs
Depending on the type and complexity of the equipment a company runs, maintenance costs can be one of the biggest financial sinkholes.
A preventive maintenance plan can help circumvent this problem by eliminating any chances of a major breakdown or deterioration.
Factories and industrial firms can really benefit from preventive efforts since they operate the most mechanical equipment of any entity.
Here are some of the ways preventive maintenance brings down upkeep costs:
Maintenance technicians discover potential malfunction points before they occur
Cleaning and detailed observation highlights breakage indicators
Low-complexity tasks consume fewer resources
A smaller team of maintenance workers can manage a greater range of tasks
High-level technical experts don’t need to be hired for the relevant roles
Furthermore, companies now have the added benefit of preventive maintenance software. These systems can provide regular maintenance checklists and help coordinate company-wide maintenance efforts.
Early Detection of Malfunction Symptoms
Disassembling and thoroughly observing equipment and facility installations is one of the basic preventive maintenance activities.
While it’s the best way to clean and polish equipment from the inside out, it also serves to reveal some obscure faults that would go undetected by a surface diagnosis.
Production lines can specifically benefit from early detection since they are the most prone to causing excessive downtime.
Here are some of the ways preventive measures aid early detection:
Machine disassembly reveals cavities and facets that are not visible from the outside
A thorough examination reveals performance dampening
Occasional replacement of dirty or slightly faulty parts may eliminate many serious defects
Installation of new functional software can implement auto diagnostics and fault-detection
Both major and minor malfunctions can be detected in a singular maintenance run
Additionally, some computerized maintenance management software (CMMS) systems develop an IoT infrastructure that centralizes equipment performance reports. A single manager could potentially discover faults before they cause serious damage.
Reduced Overall Downtime
Both static installations and running machinery need to be either partially or completely shut down for maintenance procedures.
Preventive maintenance is almost always quicker and less resource-intensive than other forms of maintenance.
This is because most modern running systems such as production lines and electrical equipment have performance management sensors that highlight singular problem areas. These can then be singled out and repaired, instead of having to shut down the full system.
Some of the advantages of preventive maintenance toward reduced downtime include:
No/less need to bring in compensatory machinery
Faster repairs due to customized preventive maintenance protocols
Sustained equipment reliability prevents future downtime
Eliminates production-line breakdowns and performance hampering
Allows the company to meet production goals with minimal technical input
Overall, preventive maintenance usually lets managers run production with basic maintenance procedures, instead of more complex and time-consuming ones.
Automate Work Orders
Create triggers and automate your work order tasks. Simplify your life by letting Limble do the work for you.
Reduce friction between your whole team. Manage and schedule everything and watch the results come in.
Emergency maintenance is the most expensive and the most dreaded form of maintenance by companies running high-value production equipment.
This is especially true for companies with a lot of high-tech machines such as large scale 3D printers, microelectronics, and/or biotech plants.
Regular preventive maintenance provides these companies with a virtual safety net from these problems, with added protection from resource wastage.
Preventive upkeep several benefits towards minimizing emergency instances, including:
Little to no need for emergency equipment and parts procurement
Fewer reactive maintenance measures to conduct
Reduction in detailed repair and replacement management procedures due to regular basic observation
Constantly running systems such as elevators, ventilation, and HVAC systems have improved reliability
Static fixtures have improved service life and cosmetic quality (in the case of decorative installations)
Additionally, one comprehensive PM program can potentially render most emergency maintenance plans obsolete, or at least reduce their requirement.
Prolonged Asset Life
Every piece of equipment has a certain lifespan after which it will need either varying degrees of repair or replacement (run-to-failure systems).
Companies usually procure such equipment after considering how long it will run and how much it will produce on a timely basis. While they already consider the repair or replacement costs beforehand, it’s still a benefit if maintenance measures can prolong equipment life.
That’s exactly what preventive maintenance does, even for disposable items such as lighting units.
Here are some of the ways preventive maintenance prolongs asset health and overall life:
Helps detect and clear even the most minor faults
Lets technicians judge whether a small adjustment or modification can be made to improve the running capacity of machines
Allows machines to run cleaner, with fewer recalibrations needed
Lets senior maintenance managers calculate asset depreciation to make better procurement decisions in the future
Provides an entry point for effective computerized maintenance management systems for real-time performance monitoring
Additionally, preventive maintenance provides a clear picture of how long a certain piece of equipment is meant to run, and what maintenance procedures can be implemented to get more service out of it.
Smaller Waste/Scrap Production
It’s no secret that the faulty or incomplete products that customers get in the market are often the result of defective machinery.
Poorly operating machines not only consume more power and streamlining substances (grease, oil, etc), but also slow down production, sometimes to a halt.
Preventive maintenance not only makes sure that no machine is running at less than optimal efficiency but also protects brand reputation by ensuring that bad products don’t fall through production cracks.
Here’s how preventive maintenance benefits waste reduction measures:
Regular upkeep ensures asset operation as per original specifications
More time to monitor and repair during the PM phase provides added opportunities for defect-detection
Saves on repair costs for more delicate parts which could be a bigger cause of scrap
Early detection allows engineers to develop better production parameters
Prevents late delivery while could result in wasted products
On top of all that, some PM plans have built-in waste-reduction protocols that prepare companies for more waste-free production.
Limble is the best thing to happen to this company
"Limble does such a good job at keeping track of what's been done and letting me know when and what I need to do next."
— Tom Jones
Little Giant Ladder Systems
Awesome Product with REAL support!
"Our team reviewed & demoed 6 different CMMS companies and the decision was easy! The functionality was extremely easy, but still provides the analytics needed to track our companies time and money spent on maintenance. Their support is top-notch! I've dealt with numerous software companies in my position and can tell you, you will not find one better!"
— Jason Mathern
Wow. You guys are amazing...
"Wow. You guys are amazing... your software really one-up's the competition. I've found several with some of the functionality, but much clunkier designs. I reviewed 16 CMMS packages, and yours was an easy choice. Thank you again. Well done."
— Loren Overby
A must for any maintenance department
"The thing that I loved the most right from the start was the ease of use of the Limble software. The customization options available when setting up PM's are great. I love the flexibility it gives to tailor the PM to exactly what your needs are."
— Richard Dunaway
Over all very good
"Nice layout and easy to use. Email alerts are very useful, and the comparison between planned and unplanned is very helpful"
— Paul Sheppard
"Great experience. Solved our obvious PM tracking issues but also addressing our SHE&S requirements (safety audit task tracking), Environmental checks are being logged, Corporate Audit items tracked"
— Michael Babcock
Great user friendly product
"Love the fact that the product can be used on my phone, tablet, and laptop. It also has made several updates to make an even better product."
— Dave Stern
Great for smaller or larger facilities
"We haven't fully integrated Limble yet but we are already seeing improvements in our efficiency. As we fully integrate Limble we expect to see more benefits and increase our response and completion times. The customer support has been outstanding. The Limble team is very quick to respond to any questions and they are very open to suggestions."
— Mike Hill
Children's Home of Lubbock
Best value for money CMMS
"Limble has all the features essential to maintenance management. It is very easy to use. Limble can connect with wireless sensors for Condition Based Maintenance. We are in Thailand, and Limble also supports the Thai language. Importantly, their customer support is fantastic almost 24/7. They reply within 10 minutes anytime. I am sure that Limble will really help your operations."
— Natee Singhaputtangkul
Very well written software. Easy to use.
"The support is fantastic. The guys who support this software even email you to check in from time to time. If you have any issues you can call directly, and get instant help!"
— Dan Velente
Five star program
"This is one of the most easiest CMM Systems I have used. With unbelievable response times to questions. The Limble staff is very helpful. With this system, our equipment downtime has been cut by 20%."
— Gordon Shanks
Sunbelt Forest Products
Very easy to use, access
"I like the price, the fact I can see it on my phone or the computer. I like that it is internet-based."