Preventive Maintenance: The Scheduled Approach
Preventive maintenance means performing tasks at fixed intervals—whether time-based, cycle-based, or hour-based—regardless of the equipment's current condition. It is typically based on manufacturer recommendations, historical failure data, or regulatory requirements.
Common preventive tasks in industrial settings may include:
- Replacing drive belts and filters on a schedule
- Re-greasing bearings at fixed intervals
- Re-torquing electrical connections periodically
- Calibrating instruments on a regular cycle
Strengths
- Straightforward to plan and schedule
- Requires no specialised monitoring equipment
- Works well for components with predictable wear patterns
- Satisfies regulatory and insurance requirements
Weaknesses
- Risk of replacing parts that still have significant remaining life
- Time-based schedules do not catch random failures between intervals
Predictive Maintenance: The Condition-Based Approach
Predictive maintenance uses monitoring data—vibration, temperature, oil condition, electrical signatures, ultrasound—to detect early signs of degradation and schedule repairs before failure. Rather than replacing on a calendar, you replace when the data suggests a component is approaching its end of life.
Common predictive techniques in industrial plants include:
- Vibration analysis on rotating equipment
- Infrared thermography on electrical panels and motors
- Oil analysis for hydraulic systems and gearboxes
- Ultrasonic testing for compressed air leaks and bearing condition
- Motor current signature analysis for detecting rotor and mechanical issues
Strengths
- Maximise component life by only replacing what shows degradation
- Developing faults caught early for planned repairs
- Data builds a useful picture of each asset's behaviour over time
Weaknesses
- Requires investment in monitoring equipment and expertise
- Not every failure mode is detectable through monitoring
- Requires discipline in data collection and action
- Initial period provides limited insight before baselines are established
Which Strategy for Which Assets?
A common approach is to match the strategy to the asset's criticality and failure characteristics.
Critical Assets
Large motors, gearboxes, compressors
High-Wear Consumables
Filters, belts, lubricants
Safety-Critical Systems
Emergency shutdowns, safety interlocks
Non-Critical Assets
Low failure impact equipment
When External Specialists May Help
Many predictive maintenance techniques require specialised equipment and interpretation skills that may not be practical to maintain in-house. Advanced vibration analysis, thermographic surveys, oil analysis, and high-voltage partial discharge testing typically require trained specialists with dedicated equipment.
- Advanced vibration analysis
- Thermographic surveys
- Oil analysis
- High-voltage partial discharge testing
Rather than investing in full-time predictive maintenance staff, many facilities bring in specialists for periodic condition monitoring visits—quarterly vibration routes, annual thermographic surveys, and on-demand diagnostic investigations. This is one area where platforms like FindFST can connect you with the right specialist without a long-term staffing commitment.
- Quarterly vibration routes
- Annual thermographic surveys
- On-demand diagnostic investigations
- No long-term staffing commitment required
Disclaimer: This guide is provided for general informational purposes only and does not constitute professional, legal, or financial advice. All rates, timelines, and market data referenced are indicative estimates based on general market observations and may not reflect current conditions. Actual costs, qualifications, and regulatory requirements vary by country, industry, and project. Always verify information with relevant local regulations, obtain professional advice where appropriate, and request multiple quotes before committing to any engagement. FindFST accepts no liability for decisions made based on the content of this guide.
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