Be honest: Do you…
- Get your car checked out periodically?
- Or wait for the “check engine” light to come on to look into any issues?
Most of us are probably in the camp of response B, whether we’d like to admit it or not. And who can blame us? In today’s world, we’ve become so reliant on technology working for us that we don’t plan ahead for when it doesn’t. This harkens back to a ‘70s TV commercial for Fram oil filters. The auto mechanic says, “You can pay me now or you can pay me later.” You can spend $50 or so to get an oil change when you’re supposed to, or you can pay $4,000 for a new engine when you’ve burnt it up.
If we have this same mentality with our equipment on the shop floor – worth hundreds of thousands of dollars – there can be severe consequences, both financially and in the production and delivery of your parts.
By adopting a proactive approach to equipment maintenance, companies can anticipate and act on potential issues before they escalate, sparing them the headache of costly repairs and unplanned outages.
Predictive and Preventative Maintenance: A Quick Overview
Predictive maintenance uses data and machine monitoring tools to anticipate issues before they arise. Meanwhile, preventative maintenance involves consistently checking and scheduling servicing to keep equipment in optimal condition. Together, they help manufacturers efficiently manage their equipment, allowing for planned, strategic interventions—instead of scrambling around following an unplanned breakdown.
The Benefits of Proactive, Predictive Maintenance
If you don’t make time for maintenance, maintenance will make time for you. Here’s why you should never let equipment upkeep fall by the wayside:
Improve Your Equipment’s Lifespan
Machinery is one of the highest overhead investments for contract manufacturers. Make sure you’re protecting these significant assets by building periodic, scheduled maintenance into your process. By prioritizing maintenance, companies can extend the lifespan of their machines and ultimately save on replacement costs.
Reduce Unplanned Downtime
There’s nothing worse than having a machine go down when you’re working on a hot job with a tight deadline. A major equipment failure can result in days—or even weeks—of lost production time. Predictive maintenance helps you catch issues early, reducing the risk of unexpected downtime.
Having a proactive mindset allows you to plan machine downtime around your busiest schedules and perform routine inspections during off-peak times like evenings and weekends. That way, you can continue meeting customer demand without missing out on opportunities or revenue.
Control Your Costs
Routine maintenance might feel like an added expense, but it is a necessary investment. By planning maintenance schedules in advance, you can avoid emergency repairs that can do some real damage to your budget.
Consider the difference between scheduling a low-cost tune-up versus a complete overhaul following a breakdown—predictive maintenance keeps you on the former path. Over time, small, manageable machine maintenance costs can prevent more expensive repairs.
In addition, well-maintained equipment retains higher resale value. Taking care of your machinery makes it more attractive to potential buyers if you choose to sell it in the future.
Ensure Customer Satisfaction
Preventative maintenance doesn’t just improve productivity and reduce overhead costs—it safeguards your production schedule so you can meet your customers’ needs. When machines go down unexpectedly, you risk delaying production and disappointing customers. But by planning maintenance around your production schedule, you can avoid interrupting workflow and continue delivering on time, every time.
How to Put Predictive and Preventative Maintenance into Practice
Establish a Proactive Maintenance Schedule
Create a maintenance schedule tailored to each piece of equipment based on usage patterns, age, and other relevant factors. By making predictive maintenance part of your routine, you’re building it into the workflow, which helps to minimize disruptions. Scheduling half a day for maintenance is much more manageable than losing weeks due to an unexpected breakdown.
Utilize an ERP System to Track Machine Maintenance
Incorporating maintenance schedules and data into your ERP system can streamline your tracking process. Documenting maintenance activity, frequency, and equipment conditions over time offers insight into patterns and helps predict when future issues might arise.
Explore Maintenance Beyond Machines
Preventative maintenance doesn’t stop at machines; it extends to other critical assets that make up your shop. What happens when one of your delivery vehicles breaks down, or one of your forklifts is malfunctioning? When planning maintenance, be sure to consider your trucks, overhead cranes, HVAC systems, and any other equipment that is essential to your operations.
To maximize productivity and minimize costly disruptions, it’s essential to take a proactive approach to maintenance. Consider integrating predictive and preventative maintenance practices into your company’s operations—your bottom line (and your team) will thank you!
Want to learn more? Connect with your manufacturing community on NTMA Connect to find out what’s working for your industry peers.
