Design and Implement a Maintenance Strategy That Keeps Your Equipment Running at Peak Performance
Even before current market pressures, many manufacturers deprioritized preventive maintenance strategies and predictive measures, choosing to run equipment until failure. A recent survey by the National Institute of Standards and Technology (NIST) indicates that, on average, 45.7% of machinery maintenance is reactive, with only 31.8% being preventive and a mere 17.3% predictive. The findings highlight the pitfalls of reactive maintenance, such as increased downtime, defects, and costs, while demonstrating that companies focusing on preventive or predictive maintenance achieve superior outcomes across all metrics.
Nonetheless, manufacturers must judiciously allocate limited resources. This is particularly pertinent for middle-market manufacturers, which often operate with tighter budgets and smaller teams, even under favorable market conditions.
The Unsustainability of Reactive-only Maintenance
If operational demands have sidelined equipment maintenance, you are not alone. However, operating in “survival mode” has its limits. Even if your business has thus far evaded the repercussions of deferred maintenance, a cost is inevitable.
Without proper preventive maintenance, equipment failures and line interruptions are imminent—and likely to be substantial. Meanwhile, your maintenance backlog will continue to grow, becoming increasingly challenging and costly to manage.
Achieving Optimal Performance with Equipment Maintenance Planning
When fluctuations in demand, staffing limitations, or operational priorities hinder scheduling a comprehensive maintenance shutdown, a maintenance planning approach can ensure essential assets remain operational, prevent major breakdowns, and position the organization to maintain an effective maintenance program over time.
4-Step Equipment Maintenance Strategy
- Prioritize critical equipment
- Implement “running” PMs
- Capitalize on downtimes and breakdowns
- Transition to full maintenance operations
Step 1: Prioritize Critical Equipment
Begin by identifying your most crucial machinery: those that would halt operations if they failed. Then list any non-negotiable preventive or predictive maintenance strategies necessary to keep these machines running and mitigate serious safety risks.
For instance, industrial ovens used in thermoforming must be regularly cleaned and lubricated. Neglecting these basic maintenance tasks could rapidly lead to hazardous conditions, like fire risks, endangering both personnel and equipment.
Reflect on similar scenarios in your facility, but remain selective. The goal is to keep the list of essentials concise. You can always create a “B” list of maintenance tasks to address once the essentials are completed.
Step 2: Implement “Running” PMs
Using your prioritized maintenance list, identify which tasks are internal (requiring equipment shutdown) and which can be conducted externally or while the equipment is online. Keep an open mind: even if a PM has traditionally been internal, consider adjustments that could allow maintenance, or parts of it, without shutting down the machine, halting production, or needing specialized skills.
For example, we assisted a lumber mill’s operations team in replacing some machine guards with plexiglass, enabling visual monitoring of belts and timing chains without requiring equipment lockout/tagout for visual inspections. We also established valid PM procedures for external gauge and pressure checks.
In another case, we helped a milling operation implement a customized solution for regular vibration analysis. By drilling a hole in the machine cabinets and using a handheld device, we equipped the team to safely conduct checks as frequently as each shift without disrupting operations. This vibration data allows the team to anticipate spindle replacements and plan accordingly.
Potential candidates for running PMs include:
- Adding a collection vessel to gearboxes for oil sampling and continuous oil analysis, as implemented for a packaging manufacturing client.
- Utilizing automatic lubricators or fittings extending outside guards for online greasing and lubrication.
Adopting infrared analysis or heat guns for motor temperature checks as predictive measures to identify potential performance issues. - Implementing sensors to monitor various performance metrics and predict service needs.
Encourage your team to consider which maintenance tasks could be externalized in your plants. You’ll likely develop a robust list of maintenance tasks that can be performed without scheduled downtime.
Step 3: Capitalize on Downtime and Breakdowns
Some essential maintenance tasks will still require internal completion. Be opportunistic when equipment fails. Refer to your high-priority PM list from step 1 and use any forced downtime to complete as many tasks as possible.
Additionally, track information from running PMs and any predictive maintenance tools adopted, using it to keep your maintenance priority list current. If a recent PM indicates a bearing is failing on key equipment, prioritize its replacement so staff can address it at the earliest opportunity.
Step 4: Transition to Normal Maintenance Operations
Prioritizing critical equipment, implementing running PMs, and optimizing forced downtime can enhance equipment reliability and reduce disruptions. These practices form the core of a maintenance strategy aimed at preserving asset performance while managing costs.
To ensure your strategy remains effective and to determine when more extensive maintenance actions are needed:
- Monitor maintenance availability. Maintenance windows may be limited by production demands. However, as scheduling evolves, there will be periods when capacity increases, staff availability improves, and production schedules allow planned downtime. Be vigilant for these opportunities to schedule essential maintenance.
- Track OEE and downtime. Similar to extending a car’s oil change interval, excessively stretching maintenance timelines can lead to serious performance issues. Monitor efficiency, quality, and downtime metrics. If any exceed acceptable thresholds, it signals the need for more thorough preventive and predictive maintenance to sustain peak productivity and equipment longevity.
Commit to Proactive Maintenance for Future Benefits
A well-executed maintenance strategy yields lasting value across operations. By integrating preventive, predictive, and proactive practices, manufacturers can minimize downtime, enhance asset reliability, reduce maintenance costs, and extend equipment lifespan. Over time, these enhancements translate into higher productivity, safer work environments, and improved bottom-line performance. Now is the time to take charge of maintenance—not merely to resolve issues, but to build a system that upholds operational excellence.
Stay committed to a sustainable plan. Don’t postpone necessary maintenance. A four-point maintenance strategy will ensure assets operate reliably and establish superior maintenance practices for the future.
