{"id":172050,"date":"2023-10-18T10:52:35","date_gmt":"2023-10-18T14:52:35","guid":{"rendered":"https:\/\/fiix.wpengine.com\/?p=172050"},"modified":"2024-02-01T18:04:44","modified_gmt":"2024-02-01T22:04:44","slug":"essential-guide-to-comparing-types-of-maintenance-strategies","status":"publish","type":"post","link":"https:\/\/fiixsoftware.com\/blog\/essential-guide-to-comparing-types-of-maintenance-strategies\/","title":{"rendered":"The essential guide to choosing a maintenance strategy for your assets"},"content":{"rendered":"<p><a href=\"\/maintenance-strategies\/\" target=\"_blank\" rel=\"noopener\">Maintenance strategies<\/a> are complicated. Most people agree on what types of maintenance strategies exist, but that\u2019s where the consensus ends. It\u2019s rare to see eye-to-eye on what those strategies look like in the field. That\u2019s no surprise considering the number of factors that impact the debate: Cost, staff size, geography\u2014the list goes on and on. But figuring out which strategy is best for an asset is not a nice-to-have, it\u2019s essential.<\/p>\n<div id=\"toc\">\n<p style=\"margin-top: 40px;\"><strong>Table of contents<\/strong><\/p>\n<ul>\n<li><a href=\"#differenttypesofmaintenancestrategies\">Step 1: Know the different types of maintenance strategies<\/a><\/li>\n<li><a href=\"#knowyourvariables\">Step 2: Know your variables<\/a><\/li>\n<li><a href=\"#choosingamaintenancestrategy\">Step 3: Choosing a maintenance strategy<\/a><\/li>\n<li><a href=\"#bottomlinecomparingmaintenancestrategies\">Slow and steady wins the asset management race<\/a><\/li>\n<\/ul>\n<\/div>\n<h2 id=\"differenttypesofmaintenancestrategies\">Step 1: Know the different types of maintenance strategies<\/h2>\n<p>Finding the right type of maintenance strategy for an asset starts with speaking the same language. We don\u2019t need to agree on every little detail of what each strategy means, but we do need to be starting from the same spot. <\/p>\n<div style=\"display: flex; flex-wrap: wrap; align-items: center; justify-content: center; margin-top: 60px;\">\n<figure><img decoding=\"async\" style=\"margin: 0 !important;\" src=\"\/wp-content\/uploads\/2020\/01\/Reactive.png\" alt=\"Reactive maintenance\"\/><\/figure>\n<figure><img decoding=\"async\" style=\"margin: 0 !important;\" src=\"\/wp-content\/uploads\/2020\/01\/Run-to-fail.png\" alt=\"Run to fail maintenance\"\/><\/figure>\n<figure><img decoding=\"async\" style=\"margin: 0 !important;\" src=\"\/wp-content\/uploads\/2020\/01\/Corrective.png\" alt=\"Corrective maintenance\"\/><\/figure>\n<figure><img decoding=\"async\" style=\"margin: 0 !important;\" src=\"\/wp-content\/uploads\/2020\/01\/Preventive-maintenance-time.png\" alt=\"Preventive maintenance (time)\"\/><\/figure>\n<figure><img decoding=\"async\" style=\"margin: 0 !important;\" src=\"\/wp-content\/uploads\/2020\/01\/Preventive-maintenance-useage.png\" alt=\"Preventive maintenance (usage)\"\/><\/figure>\n<figure><img decoding=\"async\" style=\"margin: 0 !important;\" src=\"\/wp-content\/uploads\/2020\/01\/Routine.png\" alt=\"Routine maintenance\"\/><\/figure>\n<figure><img decoding=\"async\" style=\"margin: 0 !important;\" src=\"\/wp-content\/uploads\/2020\/01\/Condition-based.png\" alt=\"Condition-based maintenance\"\/><\/figure>\n<figure><img decoding=\"async\" style=\"margin: 0 !important;\" src=\"\/wp-content\/uploads\/2020\/01\/Predictive-.png\" alt=\"Predictive maintenance\"\/><\/figure>\n<figure><img decoding=\"async\" style=\"margin: 0 !important;\" src=\"\/wp-content\/uploads\/2020\/01\/Perspective.png\" alt=\"Prescriptive maintenance\"\/><\/figure>\n<\/div>\n<h3>Reactive maintenance\/No maintenance strategy<\/h3>\n<p><a href=\"\/maintenance-strategies\/reactive-maintenance\/\" target=\"_blank\" rel=\"noopener\">Reactive maintenance<\/a> is the mad scramble to fix a machine after it breaks down. It\u2019s like firefighters rushing to put out a fire, only there\u2019s no truck. Or hose. Or water. It\u2019s also called emergency maintenance, breakdown maintenance or simply, having no maintenance strategy.<\/p>\n<h3>Run to fail maintenance<\/h3>\n<p><a href=\"\/maintenance-strategies\/run-to-failure-maintenance\/\" target=\"_blank\" rel=\"noopener\">Run to fail maintenance<\/a> (RTF) is a deliberate choice to let an asset fail before repairing it. A plan is in place ahead of time so the assets can be fixed or replaced without causing extra delays or costs. It\u2019s like letting a light bulb burn out while having a dozen spares and a ladder ready to fix it right away.<\/p>\n<h3>Corrective maintenance<\/h3>\n<p><a href=\"\/glossary\/corrective-maintenance\/\">Corrective maintenance<\/a> is any task that corrects a problem with an asset. We reserve this type of maintenance for smaller, non-invasive tasks that happen before a machine reaches full failure, like making a fix during a routine inspection. Imagine changing the oil in your car and noticing the tires look a little flat. Pumping up the tires is classic corrective maintenance.<\/p>\n<h3>Routine maintenance<\/h3>\n<p><a href=\"\/glossary\/routine-maintenance\/\">Routine maintenance<\/a> is any task done on a planned and ongoing basis to identify and prevent problems. Routine maintenance rarely requires specialized training, skills, or equipment. The daily safety checklists many machine operators complete are an example of routine maintenance.<\/p>\n<h3>Preventive maintenance<\/h3>\n<p><a href=\"\/maintenance-strategies\/preventative-maintenance\/\">Preventive maintenance<\/a> (PM) is maintenance regularly performed on a piece of equipment in working condition to reduce the risk of it failing. There are two main types of preventive maintenance:<\/p>\n<ul>\n<li>Time-based preventive maintenance is when tasks are scheduled on an asset at a certain time interval, such as the first of every month or every seven days.<\/li>\n<li>Usage-based preventive maintenance is when work is scheduled based on the operation of equipment, such as after 1,000 miles or 10 production cycles.<\/li>\n<\/ul>\n<h3>Condition-based maintenance<\/h3>\n<p>In <a href=\"\/maintenance-strategies\/condition-based-maintenance\/\">condition-based maintenance<\/a> (CBM), the performance of an asset is monitored to determine when maintenance needs to be done. CBM uses certain indicators, like increased vibration or heat, to catch the point when failure begins, but before it leads to a breakdown. <\/p>\n<h3>Predictive maintenance<\/h3>\n<p><a href=\"\/maintenance-strategies\/predictive-maintenance\/\">Predictive maintenance<\/a> (PdM) uses condition-monitoring tools and techniques to track the performance of equipment, identify defects, and help you fix them before failure.<\/p>\n<p>The difference between predictive maintenance and condition-based maintenance lies in measurement and timing. CBM uses real-time performance data to point out a problem after a machine begins to fail. On the other hand, PdM takes all information into account (past, present, and future) and offers an ideal time for maintenance before any failure, however small, occurs. <\/p>\n<h3>Prescriptive maintenance<\/h3>\n<p>Prescriptive maintenance (RxM) takes predictive maintenance to the next level. It uses condition monitoring and machine learning tools to predict when to do maintenance, but it also lays out exactly what kind of maintenance to do to help that piece of equipment perform better for longer.<\/p>\n<div class=\"blog-table table1\">\n<h3>Maintenance strategies in action on a variable speed transfer conveyor<\/h3>\n<div class=\"blog-table-lrg\">\n<table>\n<tbody>\n<tr>\n<th>Reactive maintenance<\/th>\n<td>The conveyor breaks down with no plan in place to fix it<\/td>\n<\/tr>\n<tr>\n<th>Run to fail maintenance<\/th>\n<td>The conveyor is allowed to run until it breaks down with a plan to fix it<\/td>\n<\/tr>\n<tr>\n<th>Corrective maintenance<\/th>\n<td>A technician&#8217;s notices that a part on the conveyor is misaligned during their weekly inspection and realigns it<\/td>\n<\/tr>\n<tr>\n<th>Routine maintenance<\/th>\n<td>A machine operator inspects the conveyor before their shift to ensure it\u2019s safe and free from obvious defects<\/td>\n<\/tr>\n<tr>\n<th>Preventive maintenance (Time)<\/th>\n<td>The conveyor is inspected for potential failure every 10 days<\/td>\n<\/tr>\n<tr>\n<th>Preventive maintenance (Usage)<\/th>\n<td>The conveyor is inspected for potential failure every five production cycles<\/td>\n<\/tr>\n<tr>\n<th>Condition-based maintenance<\/th>\n<td>Maintenance is scheduled on the conveyor when vibration crosses a certain threshold<\/td>\n<\/tr>\n<tr>\n<th>Predictive maintenance<\/th>\n<td>Software says that failure-level vibration on the conveyor belt will occur in 30 days<\/td>\n<\/tr>\n<tr>\n<th>Prescriptive maintenance<\/th>\n<td>Software says that failure-level vibration on the conveyor belt will occur in 30 days and repairing it will require swapping out a certain part<\/td>\n<\/tr>\n<\/tbody>\n<\/table><\/div>\n<\/div>\n<h3>Planned maintenance vs. scheduled maintenance<\/h3>\n<p><a href=\"\/glossary\/scheduled-maintenance\/\">Scheduled maintenance<\/a> is any work that\u2019s put in the calendar, given a deadline, and assigned to a technician, whether that\u2019s done a day or a year in advance. It\u2019s the who and when of a task. <a href=\"\/maintenance-strategies\/planned-maintenance\/\">Planned maintenance<\/a> is the what, where, why, and how of a task. It doesn\u2019t always establish the exact date and time of work, but you know how to execute the work when the time comes.<\/p>\n<p>Now let\u2019s look at run-to-failure vs. reactive maintenance for example. In both cases, you don\u2019t know when maintenance is going to happen until a machine breaks down. They\u2019re both <a href=\"\/maintenance-strategies\/unplanned-maintenance\/\">unscheduled maintenance<\/a>. However, RTF is a deliberate choice. You know failure won\u2019t impact production. You\u2019ve assembled the parts, people, and processes to fix the asset quickly and without spending too much. It\u2019s planned. Reactive maintenance has none of that foresight, making it unplanned.<\/p>\n<p>Here\u2019s a handy way of remembering how to classify the types of maintenance strategies:<\/p>\n<figure><img decoding=\"async\" src=\"\/wp-content\/uploads\/2020\/01\/Planned-downtime-chart.png\" alt=\"types of planned maintenance, types of scheduled maintenance\"\/><\/figure>\n<p>And here\u2019s how much of each maintenance strategy is planned and how far in advance you can schedule them.<\/p>\n<figure><img decoding=\"async\" src=\"\/wp-content\/uploads\/2020\/01\/Planned-maintenance-vs-scheduled-maintenance.png\" alt=\"types of maintenance strategies by ability to plan and schedule them\"\/><\/figure>\n<h2 id=\"knowyourvariables\">Step 2: Know your variables<\/h2>\n<p>Every facility is different, which is why it can be maddening to talk about maintenance strategies so generally. Every asset, technician, and business is unique, and what works for one maintenance team may not work for another. That\u2019s why understanding what makes your facility tick is crucial.<\/p>\n<h3>Costs<\/h3>\n<p>Before you decide on maintenance strategies, take stock of a few key financial elements: <\/p>\n<ul>\n<li>What are you spending, all-up, on maintenance in general and for each asset?<\/li>\n<li>What\u2019s the biggest maintenance cost for each asset? Is it downtime, parts, labor, or something else?<\/li>\n<li>How much would it cost to change the strategy you\u2019re using on an asset?<\/li>\n<\/ul>\n<h3>Assets<\/h3>\n<p>Organizing your asset knowledge means it\u2019s easier to analyze and share. There are a few useful questions that can help you build a 360-degree view of your assets: <\/p>\n<ul>\n<li>How would you rank your assets by <a href=\"\/blog\/criticality-analysis-what-is-it-and-how-is-it-done\/\">criticality<\/a>?<\/li>\n<li>Which assets are underperforming against <a href=\"\/blog\/important-metrics-maintenance-department\/\">key metrics<\/a>?<\/li>\n<li>Which assets can you collect accurate data from?<\/li>\n<li>Which assets are important to safety and compliance?<\/li>\n<\/ul>\n<h3>People<\/h3>\n<p>A good maintenance strategy is only as good as people who execute it, which is why the people factor should be taken<br \/>\ninto account when building your asset maintenance strategy. There are a few questions that can help you assess the<br \/>\nbaseline of your staff:<\/p>\n<ul>\n<li>How can you get your team home safely every day?<\/li>\n<li>How many people do you have on your team and is there room for growth?<\/li>\n<li>What are the strengths and weaknesses of each person, and what training is necessary?<\/li>\n<li>How does your team spend their time?<\/li>\n<\/ul>\n<h2 id=\"choosingamaintenancestrategy\">Step 3: Choosing a type of maintenance strategy for your assets<\/h2>\n<p>Let\u2019s clear the air right now:<\/p>\n<p>\u201cThere\u2019s no single best maintenance strategy,\u201d says Stuart Fergusson, Fiix\u2019s Director of Product Management. <\/p>\n<p>\u201cThere is a \u2018worst\u2019 strategy and that\u2019s reactive maintenance, but the best strategy is the one that helps equipment function at its best, safely, and without too many costs.\u201d <\/p>\n<p>Of course, that\u2019s easier said than done. There are all those unique, colliding, and constantly changing factors for you to consider. But by looking at some major elements, such as costs, safety, and downtime, we can chart where each maintenance strategy falls and give you some tools for assessing the best one for each of your assets. <\/p>\n<h3>Cost to implement and manage vs. Instances of downtime<\/h3>\n<p>Every minute of uptime gained comes at a cost. The question is whether that cost is worth it. Our first chart can be a starting point for answering that question. It helps you measure your uptime goals against your budget and identify where resources can be used for better returns.<\/p>\n<figure><img decoding=\"async\" src=\"\/wp-content\/uploads\/2020\/01\/Cost-to-implement-manage-vs.-Instances-of-downtime.png\" alt=\"types of maintenance strategies by downtime and cost to implement and manage\" \/><\/figure>\n<h3>Cost to implement and manage vs. Asset criticality<\/h3>\n<p>A good dose of prescriptive or predictive maintenance is often enough to cure unnecessary downtime. But you know the catch: Those strategies require expensive training and technology to do well. That\u2019s where asset criticality comes in. This chart helps visualize where to dedicate your time and money to ensure the most important machines are also the most reliable. <\/p>\n<figure><img decoding=\"async\" src=\"\/wp-content\/uploads\/2020\/01\/Cost-to-implement-manage-vs.-Asset-criticality-.png\" alt=\"Types of maintenance strategies by asset criticality and cost to manage and implement\" \/><\/figure>\n<h3>Planned percentage vs. Data requirements<\/h3>\n<p>Planned maintenance is like sleep to exhausted parents with a newborn: You can never have enough. But planning takes data to be effective and efficient. The chart below is a run-down of how much data is necessary for each maintenance strategy to be successful. <\/p>\n<figure><img decoding=\"async\" src=\"\/wp-content\/uploads\/2020\/01\/Planned-percentage-vs.-Data-requirements-.png\" alt=\"Types of maintenance strategies by asset data required and amount of planning possible\" \/><\/figure>\n<h3>Planned percentage vs. Safety and compliance<\/h3>\n<p>Increased safety is often tied to planned work, because the more you know, the better you can avoid risks. This chart is all about how each strategy allows you to plan and identify risks early so you can reduce the likelihood of accidents or increase compliance on a group of assets. <\/p>\n<figure><img decoding=\"async\" src=\"\/wp-content\/uploads\/2020\/01\/Planned-percentage-vs.-Safety-risk-.png\" alt=\" types of maintenance strategies by safety and amount of planning possible \"\/ style=\"margin-bottom:0\"><\/figure>\n<div class=\"blog-table table2\">\n<h3>Ideal asset profiles<\/h3>\n<div class=\"blog-table-lrg\">\n<table>\n<tbody>\n<tr style=\"background: #F7F7F7;\">\n<th><\/th>\n<th>Reactive<\/th>\n<th>Run to fail<\/th>\n<th>Routine<\/th>\n<th>Corrective<\/th>\n<th>PM (Time) PM (Usage)<\/th>\n<th>CBM, Predictive, Prescriptive<\/th>\n<\/tr>\n<tr>\n<td><strong>Criticality<\/strong><\/td>\n<td>None<\/td>\n<td>None to low<\/td>\n<td>Low<\/td>\n<td>Low<\/td>\n<td>Moderate to high<\/td>\n<td>High to essential<\/td>\n<\/tr>\n<tr>\n<td><strong>Cost to maintain asset<\/strong><\/td>\n<td>None<\/td>\n<td>Low<\/td>\n<td>Low<\/td>\n<td>Low to moderate<\/td>\n<td>Moderate to high<\/td>\n<td>High<\/td>\n<\/tr>\n<tr>\n<td><strong>Cost of downtime on asset<\/strong><\/td>\n<td>None<\/td>\n<td>Low<\/td>\n<td>Low<\/td>\n<td>Low to moderate<\/td>\n<td>Moderate to high<\/td>\n<td>High<\/td>\n<\/tr>\n<tr>\n<td><strong>Amount of data required from asset <\/strong><\/td>\n<td>None<\/td>\n<td>Low<\/td>\n<td>Low<\/td>\n<td>Low<\/td>\n<td>Moderate to high<\/td>\n<td>High<\/td>\n<\/tr>\n<tr>\n<td><strong>Safety risk and required compliance<\/strong><\/td>\n<td>None<\/td>\n<td>Low<\/td>\n<td>Moderate<\/td>\n<td>Low to moderate<\/td>\n<td>High<\/td>\n<td>High<\/td>\n<\/tr>\n<\/tbody>\n<\/table><\/div>\n<\/div>\n<h2 id=\"bottomlinecomparingmaintenancestrategies\">Slow and steady wins the asset management race<\/h2>\n<p>Getting the right combination of maintenance strategies takes time. No one gets it perfect on the first try. No one goes from reactive to prescriptive maintenance in a single leap. Finding a formula that works is a journey. It could start with doing PMs on a handful of critical assets and lead to a well-balanced strategy that touches every machine. The in-between can last years. What will get you there are data-driven decisions. The result is a facility that runs with fewer interruptions, a healthier bottom line, and a more efficient maintenance team.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Maintenance strategies are complicated. Most people agree on what types of maintenance strategies exist, but that\u2019s where the consensus ends. It\u2019s rare to see eye-to-eye on what those strategies look like in the field. That\u2019s no surprise considering the number of factors that impact the debate: Cost, staff size, geography\u2014the list goes on and on. But figuring out which strategy is best for an asset is not a nice-to-have, it\u2019s essential. Table of contents Step 1: Know the different types of maintenance strategies Step 2: Know your variables Step 3: Choosing a maintenance strategy Slow and steady wins the asset management race Step 1: Know the different types of maintenance strategies Finding the right type of maintenance strategy for an asset starts with speaking the same language. We don\u2019t need to agree on every little detail of what each strategy means, but we do need to be starting from the same spot. Reactive maintenance\/No maintenance strategy Reactive maintenance is the mad scramble to fix a machine after it breaks down. It\u2019s like firefighters rushing to put out a fire, only there\u2019s no truck. Or hose. Or water. It\u2019s also called emergency maintenance, breakdown maintenance or simply, having no maintenance strategy. [&hellip;]<\/p>\n","protected":false},"author":42,"featured_media":172098,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[155,2],"tags":[],"coauthors":[373],"class_list":["post-172050","post","type-post","status-publish","format-standard","hentry","category-asset-management","category-blog"],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v26.9 (Yoast SEO v27.5) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>Guide to 9 Different Types of Maintenance Strategies | Fiix<\/title>\n<meta name=\"description\" content=\"Learn how different types of maintenance strategies compare to each other and how to choose the right combination of strategies for your assets.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" 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