Predictive, Preventive, and Reactive Maintenance methods compared

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These three forms of maintenance management are compared below. They are listed in order of effectiveness (highest to lowest).

Predictive Maintenance (aka Condition Monitoring): most-effective maintenance paradigm

Advantages Disadvantages
  • Continuous monitoring detects the onset of component problems in advance.
  • Maintenance performed only when needed and may be planned in ahead of time.
  • Result: cost savings of another approximately 18% when compared to preventive maintenance.
  • Reduced costs for machine and process downtime.
  • Reduced costs for manpower and replacement parts.
  • High initial costs for standard-monitoring systems and /or contracted services to perform them: e.g., as thermography and vibration analysis.

Preventive Maintenance: somewhat-effective maintenance paradigm

Advantages Disadvantages
  • Reduced machine downtime (failure rate) due to scheduled maintenance intervals.
  • This can result in cost savings of approximately 12% when compared to reactive maintenance.
  • Time-scheduled based maintenance leads to high labor costs and expensive part replacements since components with remaining lifetime might also be replaced.
  • Unplanned downtime can't be excluded.

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Reactive Maintenance: least-effective maintenance paradigm

Advantages Disadvantages
  • "Run it until it fails": this antiquated concept concept reduces maintenance costs on equipment ... until the equipment fails.
  • Unplanned downtime due to equipment failure leads to high costs.