MAINTENANCE

Maintenance contains all range of activities, including functional checks, servicing, repairs, and
replacements. Its plays a pivotal role in ensuring the smooth operation and longevity of devices,
equipment, machinery.
Maintenance functions are broadly categorized into maintenance, repair, and overhaul (MRO)
THE DIFFERENT TYPES OF MAINTENANCE
• Preventive Maintenance
• Corrective Maintenance
• Predictive Maintenance
• Condition-based Maintenance
• Reactive maintenance
PREVENTIVE MAINTENANCE (PM)
Preventive maintenance involves proactive measures taken to prevent breakdowns and defects
before they occur. It includes regular inspections, servicing, and the replacement of worn-out
parts. preventive maintenance seeks out and repairs more minor issues and decreases the
occurrence of major repairs.

Prevent maintenance includes regular and periodic (time-based) schedules.

An excellent example of preventative maintenance is the seasonal cleaning of an HVAC unit.

Corrective Maintenance (CM)

Corrective maintenance, often referred to as “breakdown maintenance,” focuses on fixing
failures and issues as they arise. The goal of corrective maintenance is to bring systems back to
regular operation as quickly as possible. With corrective maintenance, there is no program for
regular maintenance. A problem must be present before maintenance occurs.
This type of maintenance occurs when an issue is noticed.
Examples of corrective maintenance include:
▪ Repairing a broken HVAC unit rather than maintaining it.
▪ Repairing an HVAC unit after data from the unit shows it is not functioning at peak
performance.

Predictive Maintenance (PDM)

One of the more advanced ways to conduct maintenance tasks, predictive maintenance, is data-
driven. Data supplied by the equipment indicates when maintenance is needed. Data also is a
means to map when the failure of the machine may occur.
By monitoring equipment in real-time, predictive maintenance allows for better resource
allocation and cost-effective repairs. In India, the adoption of predictive maintenance is
increasing, especially in power plants and railways.
Predictive maintenance is data-driven and impacted by preset parameters.
Examples of Predictive Maintenance
▪ A sensor in an engine monitors misfires and alerts maintenance that engine service is
needed.
▪ A sensor on a refrigeration truck monitors the internal temperatures of the truck and alerts
the driver when the internal temperature falls outside acceptable parameters.
These alerts do not necessarily mean a complete failure occurs, but that condition is approaching
a range where catastrophic failure can occur.
Condition-based Maintenance
Condition-based monitoring is a scenario where maintenance is provided based on the condition
of a machine. For instance, if you are monitoring equipment or machines for abnormal
temperatures or heat changes, you can use IoT sensors to monitor their data in real-time
continuously.
As soon as you see any abnormal shift in the machine’s temperature, you can undertake the
maintenance procedure.
Reactive maintenance
Reactive maintenance is just one scenario different from corrective maintenance. As compared to
corrective maintenance, reactive maintenance is only provided after the issue has occurred.
On the other hand, corrective maintenance can also be provided in case any potential signs of
issue are there
he Real Difference Between Maintenance & Repair
Maintenance and repair are like two best friends. They’re different but go hand-in-hand together!
Maintenance helps prevent things from breaking, while repair fixes things after they’ve gone
boop! Think of it this way: if you keep eating your veggies, you’ll be strong, and your health will
improve. But if you get your hand scratched, it will only get fixed with a band-aid!
The difference between both can be defined as,
Maintenance is the prevention. While Repair is the cure.
Repairs are done to restore the functionality of equipment in case it gets damaged, breaks, or
stops working. Maintenance involves routine tasks, as well as corrective and preventive repairs,
aimed at preventing damage and extending the equipment’s lifespan
REGARDLESS OF THE TYPE OF MAINTENANCE: WHAT ARE GOOD
MAINTENANCE PRACTICES?
Good maintenance practices are essential to ensure the longevity, efficiency, and safety of
equipment. Implementing these practices can help prevent unexpected breakdowns, optimize
performance, and reduce overall maintenance costs. Here are some good maintenance practices
that can be integrated with the various types of maintenance discussed earlier:
1. Regular Inspections and Checkups: Routine inspections are vital for identifying
potential issues before they escalate. This aligns well with preventive maintenance, where
regular check-ups can help avert crises.
2. Scheduled Maintenance: Establish a maintenance schedule based on manufacturer
recommendations or operational needs, as seen in predetermined maintenance. This
ensures that maintenance tasks are performed at optimal intervals.
3. Documentation: Keep detailed records of all maintenance activities, including
inspections, repairs, and replacements. This documentation helps track the equipment’s
history and can be crucial for condition-based maintenance.
4. Use of Technology: Leverage maintenance management software, such as ToolSense, to
streamline maintenance processes. These tools can automate scheduling, track
maintenance history, and monitor equipment conditions in real-time.
5. Predictive Analytics: Implement predictive maintenance by using data and advanced
analytics to forecast when maintenance should be performed. This practice helps in
reducing downtime and preventing major failures.
6. Training and Skill Development: Ensure that maintenance personnel are well-trained
and updated with the latest techniques and safety protocols. Skilled workers can perform
maintenance tasks more efficiently and safely.
7. Spare Parts Management: Maintain an adequate inventory of spare parts to ensure
quick repairs and minimize equipment downtime. This practice is particularly important
for corrective maintenance when immediate repairs are needed.
8. Safety Compliance: Adhere to all relevant safety regulations and standards to ensure a
safe working environment. Regular safety inspections and compliance checks are crucial
components of a comprehensive maintenance program.
9. Reactive Measures: While proactive maintenance is preferred, being prepared for
reactive maintenance is also important. Have a plan in place for dealing with unexpected
equipment failures to minimize disruption.
By integrating these practices, businesses can enhance the effectiveness of their maintenance
strategies, ensuring that equipment operates smoothly and efficiently. Using modern tools like
the ToolSense Asset Operations Platform can further simplify and optimize these maintenance
processes, providing a comprehensive solution for all maintenance needs
 MAINTENANCE PLANNER
A maintenance planner is a professional who plans, schedules, and coordinates maintenance
activities for an organization’s critical assets.
Also A maintenance planner is responsible for planning and scheduling maintenance activities,
ensuring that equipment, machinery, and other assets are regularly maintained to prevent
breakdowns and downtime.
Maintenance planners work collaboratively with other maintenance staff, engineering teams, and
project managers to ensure efficient and effective maintenance of equipment and machinery.
Steps in Creating a Maintenance Plan
Here are the essential steps in creating a maintenance plan:
• Identify Equipment and Resources: The first step in creating a maintenance plan is to
identify the equipment and resources requiring maintenance. This could include
machines, vehicles, buildings, and other physical assets.
• Assess Maintenance Needs: After identifying the target equipment and resources, assess
their maintenance needs. This could entail the frequency of preventive maintenance,
condition monitoring techniques, repair assessment, and staff required for maintenance.
• Develop a Maintenance Schedule: With the maintenance needs established, create a
maintenance schedule. This schedule should include a routine maintenance plan,
emergency maintenance procedures, and identify specific personnel responsible for each
task.
• Procure Necessary Tools and Resources: Ensure that you have all necessary tools,
equipment, and resources to execute the maintenance plan. This could include anything
from standard maintenance supplies like oil, filters, and lubricants to specialized
machinery such as hoists and cranes.
• Document the Maintenance Plan: Documenting the maintenance plan is crucial for
ensuring the maintenance plan is consistently followed. The maintenance plan should be
properly labeled, documented, and made accessible to all maintenance staff.
Factors to Consider When Creating a Plan
When creating a maintenance plan, several factors must be considered to ensure its effectiveness.
These factors include:
• Budget: The maintenance plan should align with the organization’s budgetary allocation
for maintenance.
• Equipment Age: Older equipment might need more maintenance and repairs than new
equipment, which could affect the maintenance plan’s schedule.
 • Safety Protocols: It is crucial to incorporate safety protocols into the maintenance plan to
prevent accidents caused by improper handling of equipment.
• Environmental Changes: Changes in temperature, humidity, and other environmental
factors could impact the frequency of maintenance needs and techniques required.
• Staff Competence: The maintenance plan should align with the team’s skill set. It is
advisable to equip staff with necessary training and resources to enhance their ability to
execute the maintenance plan.
Tools and Resources for Creating a Plan
Several tools and resources could make creating an effective maintenance plan more
manageable. Here are some of them:
• Computerized Maintenance Management System (CMMS): This software platform
assists in managing preventive and corrective maintenance, procurement of supplies, and
labor scheduling.
• Maintenance checklists: Checklists are useful for assessing equipment systems and
identifying maintenance needs and risks.
• Smart Maintenance Sensors: Smart Maintenance Sensors make use of IoT devices to
monitor equipment condition and identify anomalies in real-time.
• Maintenance Manuals: Manuals are useful for identifying OEM-recommended
maintenance schedules and techniques.
What are the top skills required to become a maintenance planner?
• Strong technical skills
• Problem-solving
• Leadership skills
• Clear communication
• Logical thinking
• Teamwork skills
10 types of maintenance tools
Gloves, safety goggles, ear protection, dust mask and respirators
Tool box, lockers and tool belts
Power drill, circular saws, impact wrenches
Screw drivers, hammers, hand saw
 WHAT IS A CMMS
A computerized maintenance management system (or CMMS software) is software that helps
maintenance teams manage all their maintenance activities in one place. That includes being able
to plan, track, measure, and optimize everything from work orders to inventory and reporting. To
sum it up, a CMMS is what maintenance teams at industrial, asset-intensive companies use to
organize information, make sure work gets done, and measure the impact of that work.
CMMS software provides the platform and workflow to manage your maintenance operation,
including reactive maintenance, preventive maintenance, and predictive maintenance. A
CMMS solution centralizes facility maintenance information, enabling you to automate any asset
maintenance task.
A CMMS also eliminates paperwork and time-consuming activities, thereby freeing the staff to
take on more important tasks and enabling them to be more productive and proactive.
WHO USES CMMS SOFTWARE?
Maintenance manager
A maintenance manager is heavily involved in choosing a CMMS and CMMS implementation.
Once in place, maintenance managers can use a CMMS to create, schedule, and prioritize work
orders, build reports, purchase parts, and more.
Facility management and/or operations management
Facility and operations managers use a CMMS to see maintenance information, schedules,
metrics, and performance across facilities to plan production, create budgets, prepare for audits,
and buy inventory.
Reliability engineer
Reliability engineers use the data collected to collect and access data about the performance of
assets and every activity that might have impacted that performance. They can run reports and
create processes within the CMMS that reduce downtime, boost efficiency, and cut costs.
Inventory manager
Inventory managers use a CMMS to ensure the maintenance team has the right parts, in the right
place, at the right time. They do this by logging and viewing information on spare parts, setting
minimum quantities, and sending purchase requests through the software.
Health and safety personnel
Maintenance software helps your health and safety team collect information for audits, accident
reports, risk analysis, and more. They can organize and find certifications, policies, checklists,
and audit results in seconds.
Technician
Technicians are the ones using the CMMS the most. They can view work orders, receive
notifications, add information to asset profiles, and do other tasks essential for the repair and
inspection process.
Production personnel
Line supervisors and machine operators use CMMS software to submit work requests and add
details to work orders so issues are caught early and fixed quickly. Operators can also be
assigned basic maintenance in a CMMS, which frees up technicians for larger, skilled jobs.
Contractors
Contractors use maintenance software to view work orders, task lists, SOPs, and other resources
while also being able to add notes and complete tasks.
Executives and senior leadership
Business leaders use a CMMS to understand the performance and impact of maintenance across
the business, allowing them to make decisions about resourcing and capital expenditures.
The IT department
Having access to a CMMS allows the IT team to monitor integrations, software updates, and data
storage and security tasks undertaken by the software provider.
What features does a CMMS have?
When looking to buy a CMMS, there will be standard features that any high-quality
computerized maintenance management system will have, including work order management,
scheduled maintenance planning, asset management, inventory management, maintenance
reporting, and a mobile app. By using those CMMS features, you’ll be able to solve 90% of your
maintenance problems. Think of the challenges your maintenance team faces every day.
Breakdowns, backlog, missing parts, cost overruns—the list goes on. With CMMS maintenance
software, you have an incredibly powerful tool that helps eliminate these headaches.
Work order management
A CMMS helps you create, complete, and track digital work orders by allowing you to:
• Submit, review, filter, assign, and analyze work orders
• Schedule and trigger maintenance
• Get alerts when work orders are created
• Add checklists, manuals, and notes to work orders
What are the benefits of a CMMS?
A CMMS offers six specific benefits that empower your operation, including cost control,
downtime reduction, efficiency increase, centralized information, increased health and safety,
and reporting and analytics. Here are a few examples of how a cloud-based CMMS can benefit
your maintenance team.

WHAT IS THE BEST CMMS SOFTWARE?

The best CMMS software for you will depend on the needs of your team and operations. There
are three specific aspects to look for when choosing a CMMS, including if it’s easy to learn and
use, if it can integrate with your existing systems, and if you’re able to get quick access to
customer support

CMMS Software Types

1. Cloud-Based CMMS Software

Consider your hosting options before settling on a CMMS. If you have the appropriate IT staff to
assure data security and the effective working of the servers, then a CMMS installed on your
servers is an option.

Spending that much money is too much, right? In a word, yes. Switch to a CMMS hosted on the
Cloud. There’s no need for you to install anything; the data is saved by the app’s editor. Your
CMMS is accessible whenever, anywhere. This is the basic idea behind drives, the digital areas
that provide the exchange of data such as files, images, and calendar entries. These are smart
meter readings and workflows, after all, and CMMS does a lot more besides processing data and
facilitating interactions. If you want CMMS for manufacturing & energy plants if you can try
cloud-based CMMS software

2. Open-Source CMMS Software

Open source is another type of CMMS software. A computer program whose source code may
be freely accessed by anybody is known as an open-source computerized maintenance
management system. This means the most dedicated nerds may upload their bits of code to a
universally modifiable program.

One must distinguish open-source from free software, which promotes free software, for the sake
of accuracy. Fortunately, no open-source CMMS exists. However, this is not really an issue. The
main advantage of open-source software is the ability to bend the software to your needs. CMMS
Software like CloudApper CMMS lets you do just that.

3. On-Premise CMMS Software

Usually, on-premise CMMS software is hosted on the private cloud. The software is accessed
using only the organization’s network. From the purchase of the equipment through the
execution and beyond, you are fully responsible.

You must supply the IT infrastructure on which the CMMS software will function, set up the
network to allow user access, and install any updates or security patches. You will be responsible
for your own backups, security, setup, licensing (if required), integration, and support charges as
well (which are usually very expensive). Installing upgrades may be a difficult task.

CloudApper CMMS Software

Now we understand the major types of CMMS software but the real question is which one is
better for your business? Well, that will depend on your business needs and requirements. But if
you are looking for CMMS Software with the ability to be personalized and that also can be
hosted on-premise as well as be accessible from the Cloud, try CloudApper CMMS. Currently,
it’s one of the most versatile CMMS Software in the market right now. Get in touch with
CloudApper for a FREE DEMO.