PREVENTIVE MAINTENANCE

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Preventive maintenance is a critical practice in many industries. Essentially, this approach aims to increase operational continuity and efficiency by conducting regular maintenance of equipment or systems, identifying potential issues beforehand, and preventing potential problems. Preventive maintenance extends the lifespan of equipment, reduces operating costs, and helps prevent unexpected failures and downtime. In this context, it is an essential strategic method for many industrial companies.

What are the Types of Preventive Maintenance?

Preventive maintenance can be performed using different methods and strategies. These techniques are listed as follows.

  • Predictive maintenance: Based on machine life, performance data, and other factors, this approach aims to predict future failures. Thus, preventive maintenance can identify and resolve issues before they occur.
  • Time-based maintenance: This method involves performing planned maintenance activities at specific intervals. For example, maintenance can be performed after a certain period or operating hours.
  • Condition-based maintenance: Monitors the operating condition of equipment and triggers maintenance when specific criteria or thresholds are exceeded. Sensors and monitoring systems are often used in implementing this method.
  • Preventive replacement: A technique that involves replacing equipment or system components after a specific period or operating cycle. This is planned considering the wear and tear processes of the components.
  • Protective maintenance: A type of preventive maintenance that ensures protection of equipment against environmental influences. It may include routine tasks such as lubrication, cleaning, and leak testing.

These methods are often used together, and the ones most suitable for a business's needs, equipment characteristics, and operating conditions are selected. This diversity enhances the flexibility and effectiveness of preventive maintenance.

Examples of Preventive Maintenance Planning

Preventive maintenance plans should be customized and optimized according to the characteristics and needs of the business. These plans should include specific systematic elements. For example, dates for equipment maintenance and application steps should be determined, faulty safety systems should be identified, and details such as heat and vibration measurements should be planned for preventive maintenance applications. Additionally, repair priorities identified through risk analyses and situation analyses conducted with physical evidence are essential.

For example, when creating a machine maintenance plan in a production facility, the machine's operating hours and dates can be considered. Routine maintenance can be performed after a certain period or operating hours. This maintenance may include simple tasks such as lubrication, cleaning, and filter replacement. A plan can be created for periodic review and replacement of parts affecting performance when needed. Moreover, preventive maintenance planning in a power plant may be more complex. Here, overhauls or major component replacements may be scheduled after a specific period or operating cycle.

Sensor and monitoring systems continuously observe the condition of the equipment and generate maintenance requests automatically when a specific threshold is exceeded. Reviewing historical data is also essential for creating preventive maintenance plans. This data can be used to determine which equipment requires maintenance at what frequency and which types of failures occur more frequently. Thus, the most effective and efficient preventive maintenance plan can be created, enhancing the continuity and efficiency of the business.

What are the Advantages of Preventive Maintenance?

Preventive maintenance offers many advantages in increasing the continuity and efficiency of a business. These are listed as follows.

  • Preventive maintenance minimizes unexpected downtime by detecting potential equipment failures beforehand. This increases operational continuity and reduces production interruptions. Preventing failures can significantly reduce production losses and costs.
  • Regular maintenance extends the lifespan of equipment. Part replacements, lubrication, cleaning, and other maintenance activities enhance equipment performance and reduce wear rates.
  • Regular maintenance ensures the equipment maintains optimal performance. Well-maintained and clean machines operate more effectively and consume less energy. Additionally, regular adjustments and revisions ensure the equipment delivers its best performance.
  • Preventive maintenance reduces the costs of unexpected failures and major repairs. Small regular maintenance expenses are more economical than the high costs of unexpected major failures. Increased operational continuity and reduced production losses also lower costs.
  • Regular maintenance enhances workplace safety. Well-maintained equipment reduces safety risks in the workplace. Early detection and prevention of hazardous situations prevent accidents and injuries.
  • Efficiently operating equipment enables the production of high-quality products. High-quality products increase customer satisfaction. Therefore, preventive maintenance has a direct positive impact on customer satisfaction and the reputation of the business.
  • Preventive maintenance plans support the timely and effective planning of maintenance activities. They allow the business to use its resources more consistently. Planned maintenance activities also enable better planning of the business's other operations.

Preventive maintenance offers attractive value in areas such as failure prevention, equipment efficiency, cost savings, increased safety, and customer satisfaction. These advantages enhance the competitiveness of firms and create sustainable business management.

What are the Differences Between Preventive Maintenance and Predictive Maintenance?

Preventive maintenance and predictive maintenance are two different maintenance strategies used in industry. Both aim to predict failures in advance and increase equipment efficiency. However, their approaches and implementation methods differ. Preventive maintenance involves regular maintenance activities planned at specific time intervals or operating cycles. It is based on standard procedures and is performed to maintain the overall health of the equipment.

Predictive maintenance, on the other hand, aims to predict future failures by monitoring the real-time condition of the equipment and analyzing data. It is carried out through sensors and monitoring systems, continuously monitoring the equipment's current condition. One of the fundamental differences between these two strategies is maintenance timing. While preventive maintenance involves maintenance activities planned at specific time intervals or operating cycles, predictive maintenance determines maintenance activities based on the real-time condition and data of the equipment. This indicates that predictive maintenance offers a more proactive approach. Additionally, while preventive maintenance includes standard maintenance activities such as lubrication, cleaning, and part replacement, predictive maintenance requires real-time monitoring and data analysis.

Both strategies are important for increasing the continuity and efficiency of a business. However, the choice between them will depend on the needs of the business and the characteristics of the equipment. Maintenance types can be applied in various sectors and can be commissioned by various stakeholders. The commissioning of preventive maintenance may vary depending on the needs and resources of the business and may require collaboration among different stakeholders.

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