How to Overcome the Challenges of Adopting Preventive Maintenance: A Five-Step Process

Preventive maintenance is a key strategy for maximising operational efficiency and minimising costs across various industrial sectors. While its benefits are well known, many companies still struggle with implementation. Shifting from a reactive (corrective) approach to a proactive (preventive) model requires changes in processes, mindset, and technology adoption.

What is Preventive Maintenance?

Preventive maintenance involves scheduled and planned actions to keep equipment running optimally before failures or breakdowns occur. This includes:

• Regular inspections

• Periodic maintenance

• Adjustments and lubrication

• Replacement of parts based on asset lifecycle

The primary goal is to reduce unplanned downtime, extend equipment lifespan, and enhance overall productivity.

Key Benefits of Preventive Maintenance

Implementing a preventive maintenance strategy brings numerous advantages, including:

1. Cost Reduction

Proactively maintaining equipment helps minimize emergency repairs and avoid costly production shutdowns.

2. Extended Equipment Lifespan

Properly maintained assets last longer, maximising return on investment over time.

3. Increased Operational Efficiency

Planned maintenance ensures better resource utilisation, reducing critical breakdowns.

4. Enhanced Workplace Safety

Regular upkeep decreases the risk of equipment failures that could pose safety hazards to employees.

Additionally, companies that adopt preventive maintenance contracts gain predictability in budgeting, reducing unexpected costs and improving service quality.

Why Are Companies Still Relying on Corrective Maintenance?

Despite the clear advantages, many companies hesitate to transition to preventive maintenance. A study by Deloitte found that a significant number of businesses still rely on corrective maintenance—only fixing issues when they arise. Key challenges include:

• Resistance to change: Many organisations are accustomed to reactive repairs due to perceived lower immediate costs.

• Lack of accurate data: Without reliable insights, companies struggle to justify preventive maintenance investments.

• High initial investment perception: Businesses without monitoring systems may see preventive strategies as expensive.

How to Successfully Implement a Preventive Maintenance Plan

A well-structured preventive maintenance plan starts with data collection and analysis. Here’s how to get started:

1. Gather Maintenance Data

   • Track past interventions, anomalies, and equipment failure rates.

   • Identify trends in breakdowns and repair frequency.

2. Prioritise Critical Assets

   • Focus on assets with high intervention rates over the past year.

   • Determine which equipment experiences frequent issues or anomalies.

3. Identify Error Indicators

   • Analyse failure patterns and root causes.

   • Define warning signs for potential breakdowns.

4. Develop a Maintenance Schedule

   • Set timelines for inspections, repairs, and part replacements.

   • Assign detailed tasks, priorities, and necessary resources.

How FullyOps Can Help

We empower businesses to take control of their maintenance processes with a data-driven, efficiency-focused approach. Our platform is designed to streamline work order management and facilitate the shift toward preventive maintenance contracts.

By centralizing and structuring detailed corrective maintenance data—such as anomalies, parts, and costs—FullyOps delivers clear insights into equipment failure trends. This allows companies to demonstrate the tangible benefits of preventive maintenance, including lower repair costs, extended asset lifespan, and optimised operational expenses.

With a proactive approach, FullyOps allows businesses build a strong case for adopting preventive maintenance strategies, ensuring a smoother and more cost-effective transition.