Maintenance is the backbone of operational efficiency, extending the life cycle of equipment and ensuring safety and reliability. In this blog, we’ll explore various maintenance strategies, their applications, and their pros and cons to help you choose the right approach for your needs.
1.Reactive Maintenance (Run-to-Failure)
Definition:
Reactive maintenance, also known as breakdown maintenance, involves repairing equipment after a failure occurs.
When to Use:
- Low-cost, non-critical systems.
- When the cost of downtime is minimal.
Pros:
- Minimal planning required.
- Low initial cost.
Cons:
- Unplanned downtime.
- Higher long-term repair costs.
Example:
Fixing a burnt-out light bulb in an office space.
2. Preventive Maintenance (Scheduled Maintenance)
Definition:
Preventive maintenance focuses on regular inspections and scheduled upkeep to prevent equipment failure.
When to Use:
- For critical equipment with predictable wear-and-tear patterns.
Pros:
- Reduces downtime and unexpected failures.
- Increases equipment lifespan.
Cons:
- Higher upfront costs.
- May involve unnecessary maintenance.
Example:
Performing regular oil changes on machinery.
3. Predictive Maintenance (PdM)
Definition:
Predictive maintenance uses real-time data and analytics to predict when equipment will fail.
When to Use:
- In high-value assets where failures have significant consequences.
Pros:
- Optimizes maintenance schedules.
- Reduces unnecessary maintenance.
Cons:
- High setup and technology costs.
- Requires skilled personnel and robust data systems.
Example:
Using vibration analysis to predict bearing failures in rotating machinery.
4. Condition-Based Maintenance (CBM)
Definition:
CBM involves monitoring the actual condition of equipment to decide on the need for maintenance.
When to Use:
- For systems with measurable performance indicators (e.g., temperature, pressure).
Pros:
- Maintenance is performed only when necessary.
- Reduces waste and extends asset life.
Cons:
- Requires monitoring systems and sensors.
- May involve significant initial investment.
Example:
Installing temperature sensors to monitor and address overheating.
5. Reliability-centred Maintenance (RCM)
Definition:
RCM identifies maintenance strategies based on the reliability and criticality of equipment.
When to Use:
- In complex systems where reliability is essential.
Pros:
- Focuses on critical assets.
- Balances cost and reliability.
Cons:
- Complex and time-consuming analysis.
- Requires detailed documentation.
Example:
Developing maintenance schedules for an aircraft fleet.
6. Total Productive Maintenance (TPM)
Definition:
TPM is a holistic approach that involves all employees in improving overall equipment effectiveness (OEE).
When to Use:
- In organizations aiming for lean operations.
Pros:
- Promotes team collaboration.
- Increases operational efficiency.
Cons:
- Requires cultural change.
- Long-term implementation.
Example:
Cross-training employees to identify and solve equipment issues.
Comparing the Maintenance Practices
Here is the comparison of different type of maintenance practise we have discussed.
| Maintenance Type | Proactive/Reactive | Cost | Complexity | Best For |
| Reactive Maintenance | Reactive | Low (initial) | Low | Non-critical systems |
| Preventive Maintenance | Proactive | Moderate | Moderate | Predictable wear-and- tear assets |
| Predictive Maintenance | Proactive | High | High | High-value assets |
| Condition-Based | Proactive | Moderate to High | High | Systems with measurable metrics |
| RCM | Proactive | High | High | Complex, critical systems |
| TPM | Proactive | Variable | High | Lean organizations |
Conclusion
Choosing the right maintenance practice depends on factors like asset criticality, operational goals, and available resources. While reactive maintenance might work for non-essential systems, predictive and condition-based strategies are essential for high-value, critical operations. Analysing your needs and long-term goals will ensure optimal results.
Actionable Advice
Its good to have implementation of a structured approach while applying these different types of maintenance practises in the plants. After analysis of the facts, we have to decide that which kind of maintenance practise we need to apply to the particular machine. For more information and knowledge, you can follow our you tube channel or contact us on below mentioned details.
Contact Us
KEC Bearings Pvt Ltd
G-2408A, F2 Road, Almighty Gate, Lodhika GIDC, Metoda – 360021, Rajkot, Gujarat (INDIA)
Website: www.kecbearings.com
Email: sales@kecbearings.com
WhatsApp: +91 9330 96 9330
