How to create a proactive maintenance strategy?

Reactive maintenance often remains highly practiced due to low initial costs. Most companies choose this approach but deal with heavy costs post-asset failure. They suffer high repair costs, wastage of time, and outputs produced due to negligence to minor failures. It also reduces the overall asset life and leads to increased investment in a new asset purchase. 

The continuous increase in investments often leads companies to shift to a proactive maintenance strategy. How about we save you the time and hassle to get you started with a proactive approach from the beginning? 

Let’s understand the meaning and adequate implementation of a proactive maintenance approach. 

What is proactive maintenance? 

Proactive maintenance is a maintenance strategy that aims to determine the root cause of machine issues before they become complex. Many minor issues often lead to equipment failure when not handled on time. This can be found early by frequently conducting maintenance inspections. Timely proactive maintenance also increases asset life span. In a nutshell, it anticipates issues before they develop significantly and increase costs. 

Difference between proactive and reactive maintenance:

Proactive maintenance works on predicting the issue before it could take place. On the flip side, reactive maintenance tackles issues after they have occurred. The latter leads to an unnecessary increases in time, effort, and investment. 

Let’s now look at some basic points of differences between the two: 

  • Time to take action: Proactive maintenance focuses on taking action before a major occurrence but reactive maintenance often starts after asset failure.  
  • Efficiency in the long run: Proactive maintenance remains cost-effective in the long run, while reactive maintenance is ineffective in the long term.
  • Asset reliability: Proactive maintenance makes assets more reliable, and assets are unreliable when you use reactive maintenance.

Types of proactive maintenance

Let’s now look at some common types of proactive maintenance: 

  • Preventive maintenance(PM): This is the most commonly practiced form of proactive maintenance that removes the possible causes of future equipment breakdown. 
  • Planned corrective maintenance(CM): It aims at ensuring the problem that occurred due to the root cause doesn’t arise again. Therefore, the steps taken are called corrective maintenance or corrective action. 
  • Predictive maintenance (PdM):  It avoids any future possibility of asset breakdown due to anticipated problems. 
  • Breakdown maintenance (BdM):  Let’s say the equipment broke or failed in certain areas. All the work done to make it functional again falls under breakdown maintenance.

Steps to implement a proactive maintenance strategy 

Now that you understand the meaning and types of proactive maintenance, let’s move to easy implementation: 

Take into account the need for preventive maintenance

Addressing the root cause of maintenance issues remains feasible when maintenance becomes more expensive considering the time and resources. Instead of a short-term gain, we plan on taking into account long-term solutions. 

Create a diverse team to take charge of preventive maintenance execution

Engage employees who can significantly contribute to the successful implementation of predictive maintenance. The people involved may include security guards, equipment operators, maintenance personnel, operations managers, and management team members. Go through your current employees and identify the person with the necessary leadership skills. 

Decide which assets you want to keep

Know which assets need maintenance and their importance in the business processes. This can help identify strengths to focus on for active support.

Review current maintenance practices

Pay close attention to ongoing maintenance activities and analyze the ones with the majority of the impact. Keep this in conjunction with maintained resources to determine which maintenance methods and tools will benefit most from implementing essential maintenance.

Check industry best practices and revise manufacturer’s instructions

Know if there are better ways to maintain the equipment and if it is still used in the workplace. Carefully read the manufacturer’s instructions for the care and use of the equipment to ensure that the correct steps are taken. Evaluate the skills of employees in the use and maintenance of equipment.

Implement service method changes and track your progress

Now you have finished deploying the updated service practices. Start monitoring to see if the implementation occurred as planned. Perform audits and collect employee feedback on the impact of changes on operations.

Use the latest technology: iAuditor.

SafetyCulture (formerly iAuditor) is preferred by companies when it comes to making maintenance changes at every level and monitoring the current performance of machines and equipment in operation. The tool remains suitable for ensuring transparency at every stage. Furthermore, iAuditor also assists companies in checking whether the previous processes have a positive impact. 

Wrapping up

Now you know the right way of shifting to the proactive mindset. Use the right tools and technology to ensure smooth implementation. You will eventually notice the increase in productivity and decreased problems associated with asset maintenance. 

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