“If it is not broke, don’t fix it.” There are times where this saying holds true, but in a safety program that attitude can cost you. An effective safety program is constantly adapting and changing to the unique environment of your business. There will be no two programs that can be run exactly the same. When developing your safety program, have you thought about how a preventive maintenance program fits in?
There are generally three types of maintenance: corrective, predictive, and preventive. Corrective maintenance is the action of fixing the equipment once it breaks or malfunctions. Predictive maintenance uses various tests and sensors to judge the condition of the equipment and fix it before it breaks. Using thermal cameras to measure the heat of a motor or bearing is one form of predictive maintenance. Preventive maintenance is planned or scheduled maintenance. Being proactive about maintenance and fixing it before it breaks can save time, money, and your employees. Replacing worn tires on your vehicle is better than having a blow out on the highway. Spending $100 on a worn fall harness is better than spending $100,000 on an injured employee.
5 Reasons You Need a Preventive Maintenance Program
Blog Contributed by MW Industrial
Let’s face it, a lot of us are guilty of not giving our equipment much thought when it’s working just fine. If it ain’t broke, and all that. The problem with this mindset boils down to dollars. Simply put, you’re going to spend significantly more money if your strategy is to simply react when an issue comes up with your equipment.
A successful preventive maintenance program improves the performance and safety of your company’s valuable assets. Equally important, regularly scheduled maintenance helps you avoid unplanned downtime.
According to Plant Engineering’s 2017 Maintenance Report, 69% of respondents have decreased downtime with a preventive maintenance program, while 66% report a reduced probability of equipment failure, 63% experienced improved overall equipment effectiveness and 62% have improved their plant’s safety.
Need more convincing? Here are 5 good reasons why a proactive preventive maintenance approach will reduce your costs and improve overall operations.
1. Save Money
Unplanned downtime caused by equipment failure can cost a fortune in lost production revenue, not to mention emergency repair costs. Back in 2006, one minute of downtime in the auto industry was found to cost a whopping $22,000.
From paying technicians overtime to the cost of overnight parts delivery, everything is more expensive in an emergency—especially when a production line goes down.
A preventive maintenance program is simply good business. How good? How about a 545% return on investment, according to a recent study from Jones Lang LaSalle? Not a bad ROI, to say the least.
2. Maximize Efficiency
Regular equipment maintenance optimizes operations so you can run at maximum efficiency. According to CMMS software company, eMaint, most maintenance organizations operate at only 10% to 40% efficiency and spend a staggering 50% of their time on emergency work.
Keeping your equipment running at optimal potential increases uptime, enhancing production while reducing costs. Poorly maintained equipment uses a lot more power, resulting in increased energy costs that add up over time. Well-maintained equipment also reduces scrap produced by machinery that’s operating at a sub-par performance level.
3. Prolong Equipment Life
Preventive maintenance programs result in longer lasting, better-performing equipment. According to Plant Engineering’s survey, aging equipment is the leading cause of unscheduled downtime. Regular maintenance protects your investment and improves both your equipment’s lifespan and performance. And as we all know, more efficient, effective equipment translates to higher profits.
4. Reduce Maintenance Costs
Reactive maintenance is widely thought to be anywhere from 2 to 5 times more expensive than preventive maintenance. Over a period of time, regularly scheduled maintenance minimizes breakdowns and makes for much quicker, easier repairs when issues do arise.
It’s simply smarter to replace components that wear down before they fail. Preventing problems before they occur is always going to be less expensive than equipment failures.
5. Improve Safety and Reliability
Poorly operating machinery can create hazards and unsafe working conditions. Dulled and warped edges on equipment with grinding gears can be dangerous. Regular maintenance inspections ensure that faulty equipment doesn’t cause injury. And when your equipment is in safe working order, your employees stay safe as well.
A preventive maintenance program can also help you earn a reputation as a reliable partner. Putting this proactive strategy in place goes a long way to helping you complete projects on time and deliver products without delay.
There are endless ways a preventive maintenance strategy can improve your operations. Implementing a successful preventive maintenance program can be time consuming and costly, but the rewards are well worth the effort.
“5 Reasons You Need a Preventive Maintenance Program | Blog | MW.” MW Industrial Services, 22 Aug. 2017, www.mwservicesinc.com/5-reasons-need-preventive-maintenance-program/