Maintenance Strategies in Manufacturing

Maintenance Strategies in Manufacturing

Maintenance Strategies in Manufacturing

Daniel Penn - How to...

By Tony Rodriguez, President, Daniel Penn Associates, LLC

Which Ones Fit Your Operations?

In a fast-paced manufacturing environment, maintenance is more than keeping machines running; it’s about optimizing production, avoiding costly downtime, and ensuring timely deliveries. As production and maintenance managers, understanding and implementing the correct maintenance strategy can be the difference between meeting your output targets and facing financial setbacks.

While most people only think of maintenance when something breaks down or stops working, in manufacturing, maintenance strategy is a proactive decision with significant financial implications. Just like changing the oil in your car before the engine seizes up, a well-planned maintenance strategy in manufacturing keeps production lines moving efficiently and prevents unplanned downtime. However, unlike routine car care, manufacturing has a lot more complexity, with several strategies to choose from.

Below, we’ll cover the latest maintenance strategies manufacturers use, explain when each is optimal, and outline how you can decide which approach fits your plant’s unique needs.

Modern Maintenance Strategies in Manufacturing

Maintenance strategies have evolved significantly. Today, manufacturers have access to advanced data and monitoring systems that offer more options beyond the traditional approaches. Let’s explore the primary maintenance strategies today, focusing on their distinguishing features, costs, and benefits.

Preventive Maintenance (PM): Planned and Scheduled

Preventive maintenance remains a cornerstone of maintenance strategy in manufacturing. PM involves scheduling regular maintenance activities before equipment breaks down, thus avoiding unplanned downtime and associated costs. Typically cheaper than waiting for equipment failure, PM is about avoiding the high costs of lost production. In manufacturing, this is often achieved through routine inspections, part replacements, and cleaning activities based on manufacturer recommendations or historical data.

Key Advantage: Reduces the risk of sudden breakdowns.

Best For: Equipment with a predictable wear-and-tear pattern. 

Reactive Maintenance (RM): Wait Until It Breaks

Reactive maintenance, also known as “run-to-failure,” involves waiting for equipment to fail before taking action. While it sounds counterintuitive, this strategy can make sense in specific scenarios, mainly when equipment is cheap to replace or downtime doesn’t heavily impact production. For instance, in the case of low-cost items like electric motors under 5hp, it’s often more economical to replace them than invest in extensive repair.

Key Advantage: No upfront investment in monitoring or maintenance planning.

Best For: Low-cost, non-critical equipment.

Predictive Maintenance (PdM): Predictive Analytics-Based

Predictive maintenance is rapidly gaining traction in the industry. This strategy uses advanced data analysis tools and technologies such as vibration analysis, oil analysis, and thermal imaging to predict when equipment will fail. Unlike preventive maintenance, which is time-based, PdM is condition-based and relies on real-time data to inform maintenance schedules. This allows for targeted interventions only when necessary, optimizing both time and resources.

Key Advantage: Minimizes unnecessary maintenance and maximizes equipment lifespan.

Best For: Critical equipment where failures result in significant downtime or repair costs.

Condition-Based Maintenance (CBM): Real-Time Condition Monitoring

Often considered a subset of predictive maintenance, CBM uses real-time monitoring systems, such as IoT sensors, to collect continuous data on equipment conditions. The data is then compared against predefined thresholds for failure, enabling maintenance teams to act before a breakdown occurs. While CBM typically requires investment in technology and training, it provides excellent control over energy consumption and maintenance timing.

Key Advantage: High efficiency in preventing breakdowns through real-time monitoring.

Best For: Complex systems with variable operating conditions, where real-time data offers an edge.

Reliability-Centered Maintenance (RCM): Holistic and Customized

Reliability-Centered Maintenance is an all-encompassing approach that incorporates multiple maintenance strategies based on the criticality of the equipment. RCM involves a detailed analysis of equipment functions, failure modes, and consequences. It aims to find the most cost-effective maintenance approach for each asset. For critical machinery, RCM might recommend predictive or preventive strategies, while less crucial equipment could be managed reactively.

Key Advantage: Maximizes reliability with the least possible maintenance cost.

Best For: Complex facilities with a diverse range of equipment and operational goals.

Trends in Maintenance Strategy Adoption

Recent studies indicate a shift towards more predictive and condition-based maintenance strategies as manufacturers strive for increased efficiency and reduced downtime. In a 2023 survey of maintenance professionals, Predictive Maintenance has gained significant traction due to the accessibility of advanced analytics and IoT-based monitoring tools. Here are the key trends:

  • Preventive Maintenance (PM) continues to have a strong presence, particularly for simpler equipment with predictable lifecycles. A Jones Lang LaSalle report demonstrated that investments in preventive maintenance can generate a 545% return on investment!  According to Plant Engineering, 88 percent of industrial facilities follow a preventive maintenance strategy for their production equipment.
  • Reactive Maintenance (RM) is steadily declining but remains common for non-critical, low-cost equipment. According to benchmarking data from the University of Tennessee’s Reliability and Maintenance Center, top quartile organizations perform about 9% reactive maintenance, average organizations perform about 31% reactive maintenance, and bottom quartile organizations perform about 62% reactive maintenance.
  • Predictive Maintenance (PdM) is becoming the go-to strategy for mission-critical equipment. Over 40% of manufacturing plants utilize predictive technologies to extend asset life and prevent failures. According to the U.S. Department of Energy’s Operations & Maintenance Best Practices Guide, predictive maintenance is cost-effective, saving roughly 8 to 12% over preventive maintenance and up to 40% over reactive maintenance.
  • Condition-Based Maintenance (CBM) is popular among facilities investing in IoT sensors and remote monitoring technologies. The manufacturing analytics market is projected to reach nearly $35.57 billion by 2029, growing at a Combined Annual Growth Rate of 19.58%. This suggests the rapid adoption of analytics technologies, including real-time data systems.
  • Recent trends in Reliability Centered Maintenance (RCM) are shifting towards data-driven and technology-enabled approaches. Manufacturers increasingly focus on integrating RCM with their computerized maintenance management systems (CMMS) to improve asset management and decision-making. There’s also more emphasis on creating a culture of reliability through employee engagement and cross-functional collaboration. Also gaining traction is the practice of integrating artificial intelligence (AI) and machine learning, allowing for more accurate failure predictions and optimized maintenance schedules.

Choosing the Right Strategy for Your Facility

Selecting the best maintenance strategy for your manufacturing operation depends on various factors, including the criticality of the equipment, the availability of resources, and the impact of downtime on production. Here are a few guidelines to help you decide:

  • For high-cost, critical machinery, consider Predictive Maintenance or Reliability-Centered Maintenance to minimize risks and optimize repair schedules.
  • For more straightforward, less critical assets, Preventive Maintenance is often the most cost-effective approach.
  • For low-cost, easily replaceable equipment, Reactive Maintenance can save unnecessary costs.
  • Condition-Based Maintenance is ideal for plants investing in IoT and real-time monitoring systems to gain more precise control over maintenance actions.
  • The right mix of these strategies, tailored to the specific needs of your equipment and operational goals, can lead to higher productivity, reduced costs, and improved asset longevity.

Finding your maintenance sweet spot

As a leader of your production and maintenance operations, your role in choosing and implementing the right maintenance strategy is critical to achieving efficient operations and maintaining equipment reliability. By adopting the latest maintenance technologies and approaches, manufacturers can not only prevent costly downtime but also optimize their resources and extend the life of their assets.

We’d love to hear how you’ve approached maintenance strategy in your facility. What strategies have worked best for you, and how have you integrated new technologies into your operations?


Ready to discuss your operational goals and challenges? We’re ready to listen. Give us a call at (860) 232-8577.

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