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Preventive or proactive maintenance refers to a maintenance strategy where assets such as machines, equipment, and devices are regularly inspected and serviced to prevent excessive wear and address potential issues by identifying them early. The goal is to extend the lifespan of equipment, maximize operational efficiency, and minimize unplanned downtime.

Advantages of preventive maintenance? 

Unlike reactive maintenance, where actions are only taken once a noticeable issue has appeared, preventive maintenance offers many benefits: 

• Minimize downtime: Regular maintenance, when properly implemented, ensures reliable operation and prevents sudden failures, thereby increasing equipment availability.   
• Reduce costs: Proactive maintenance measures help avoid expensive repairs and unplanned downtime, leading to lower maintenance expenses.   
• Extend equipment lifespan: Careful maintenance, adhering to manufacturer guidelines, can prolong the life of equipment and ensure consistent performance. This includes reducing wear through regular lubrication, timely replacement of worn-out parts, and frequent inspection of critical components.   
• Enhance safety: Regularly maintained equipment reduces the risk of accidents and hazards caused by malfunctions, improving workplace safety. 

Types of preventive maintenance: 

There are various approaches to preventive maintenance that are applied depending on the specific use case: 

• Time-based maintenance: Regular maintenance tasks are performed at fixed intervals, regardless of the current condition of the equipment (e.g., every 6 months).  
• Usage-based maintenance: Maintenance measures are carried out based on the actual usage or operating hours of the equipment (e.g., after a specific number of operating hours). 
• Condition-based maintenance: Monitoring machine parameters like temperature or vibration to detect early wear. This allows for early action without unnecessary manual efforts, such as inspecting the equipment.  
• Predictive maintenance: Utilizing data analysis, machine learning, and other technologies to predict maintenance needs (e.g., through machine learning algorithms trained on historical data). 

Example for preventive maintenance 

A practical example is the regular maintenance of a forklift. It is necessary to regularly perform oil changes to protect the engine from damage. Additionally, the brake pads need to be replaced at certain intervals before their wear leads to damage to the brake discs. These proactive measures prevent major repairs and ensure the safe and efficient use of the forklift. Ignoring the manufacturer’s instructions and extending maintenance cycles, for example, due to poor planning and prioritization, can shorten the lifespan of the forklift’s components, reduce its operational life, or result in costly repairs. 

Difference from reactive maintenance: 

While preventive maintenance focuses on proactive measures, reactive maintenance responds only  when an actual problem or failure occurs. Performing maintenance actions only after an issue has already arisen can be a cost-effective strategy in some cases. However, in the long term, it may lead to higher costs due to unplanned downtime and major repairs. Therefore, it is crucial to develop the right maintenance strategy for different assets within a company based on various criteria (e.g., type of equipment, risk of failure, impact of failure, etc.). While a reactive strategy may be the most cost-effective and suitable for less critical equipment, a predictive maintenance strategy is necessary, especially for critical, complex systems. The right mix and differentiation within the company maintain a balance between reliability and costs. 

How maintenance software supports preventive maintenance: 

A modern maintenance software (CMMS – Computerized Maintenance Management System), such as the osapiens CMMS helps companies efficiently plan and automate predictive maintenance strategies: 

• Planning: Maintenance cycles can be systematically scheduled and prioritized. The system independently generates maintenance tasks and assists the maintenance planner in prioritizing and assigning them to maintenance personnel. 
• Prioritization: The system reminds users of due maintenance tasks and minimizes the risk of forgotten activities. It helps prioritize all necessary maintenance actions and schedules notifications at the right time. For example, it assists in deciding whether an overdue maintenance task should take precedence over a newly arisen issue. Maintenance software helps to keep track and ensures nothing is overlooked. 
• Optimization: By collecting and analyzing historical data, maintenance plans can be optimized and better tailored to the specific requirements of individual equipment. This ensures continuous improvement and adaptation to the unique needs of the machinery.  

Conclusion 

Preventive maintenance is an indispensable part of any effective maintenance strategy. However, it also generates significant effort and complexity. Balanced preventive maintenance planning contributes to increased equipment availability, reduced costs, and improved safety. With reliable maintenance software, companies can streamline their maintenance processes and achieve their goals. By utilizing powerful maintenance software, companies can optimize their maintenance workflows and benefit from the advantages of preventive maintenance in the long term.