MAINTENANCE STRATEGY

Across industry, many definitions are used when it comes to the different types of maintenance. It can quickly get confusing when people talk about
preventive maintenance, Condition based maintenance or predictive maintenance but actually have something else in mind than you do. Some
people get very excited about these definitions and can spend a lot of time on for example disagreeing with what is and what isn’t preventive
maintenance. Let’s not do that, instead, I’ll offer you my view of the different types of maintenance and more importantly, when to use them.

Chittaranjan Rout
What are the types of
maintenance?
 Preventive Maintenance is done before a failure
occurs and consists of maintenance types like:-
• TBM (Time-Based Maintenance)
Preventive • FFM (Failure Finding Maintenance)
Maintenance • RBM (Risk-Based Maintenance)
• CBM(Condition Based Maintenance)
• PM (Predictive Maintenance)
 Corrective • Corrective maintenance is done
after a failure has occurred either as
maintenance Deferred Corrective Maintenance or
as Emergency Maintenance.
 At the top level, I see maintenance
being either preventive or corrective:
Preventive • When we do preventive
maintenance, we are doing a
Maintenance vs task before a failure has
occurred. That task can be aimed at
Corrective preventing a failure, minimizing the
Maintenance consequence of the failure, or
assessing the risk of the failure
occurring.
• When we are conducting corrective
maintenance, the failure has now
occurred, and we are basically
reinstating equipment functionality.
To be clear, corrective maintenance
can be the result of a deliberate run-
to-failure strategy.
Preventive
Maintenance
vs Corrective
Maintenance
Preventive Maintenance (PM):-Time-Based Maintenance (TBM)

TIME-BASED MAINTENANCE (TBM), ALSO CALLED PERIODIC

MAINTENANCE, REFERS TO ROUTINE MAINTENANCE TASKS
PERFORMED ON AN ASSET AT FIXED TIME INTERVALS,
REGARDLESS OF ITS CONDITION. AS A TYPE OF PREVENTIVE
WHAT IS TIME-BASED MAINTENANCE (PM), THE GOAL OF TIME-BASED MAINTENANCE
MAINTENANCE? IS TO PREVENT FAILURES BEFORE THEY HAPPEN AND IMPROVE
ASSET PERFORMANCE.
 Advantages
of Like other types of maintenance, TBM can be beneficial when used

TBM(Time- as part of a larger maintenance management strategy.

• Minimal Training: Time-based tasks are relatively simple and

based
usually don’t require extensive training to learn.
• Lower Long-term Cost: Compared to breakdown or corrective
maintenance (CM), time-based maintenance is relatively

Maintenance) •
inexpensive.
Easy to Implement: Time-based maintenance does not require
additional sensors or equipment to decide when assets require
service.
• Predictable Schedule: Since time-based maintenance follows a
set time interval, maintenance schedules are consistent and
predictable.
• Effective for Continuously Running Assets: Wear and tear is
more predictable for assets that run continuously, allowing
maintenance work to be scheduled at regular intervals.
Disadvantages
TBM(Time- Organizations that more depends on time-based maintenance can face some challenges:
• Ignores Other Causes of Failure: Time-based maintenance assumes that failures are
based age-related and does not take in to account the actual condition of assets. As many
maintenance professionals know, many breakdowns and failures do not occur at

Maintenance
regular, predictable intervals.
• Too Frequent Schedule Introduces Risk: A maintenance activity may introduce a
risk of incorrect re-assembly, misalignment, or other errors. A too frequent
maintenance schedule heightens this risk.
• Too Infrequent Schedule Leads to Excessive Failures: A too infrequent
maintenance schedule risks preventing predictable asset failures.
• Ineffective for Assets Run Occasionally: Assets that are used occasionally will not
wear down at the same rate as assets that are used continuously. Therefore, TBM is
not optimal for all assets, but can be used as part of a larger preventive maintenance
strategy.
• Increased Costs from Excessive Maintenance: Performing maintenance on assets
that don’t need it leads to unnecessary downtime, labor, and consumable part costs.
 As with other preventive maintenance activities, time-based
maintenance should be used to prevent failures on assets
that are critical to the organization. Using asset
When to Use management KPIs such as mean time between Failure
(MTBF), historical maintenance data, manufacturer
Time-based recommendations, and one’s own experience, the ideal
interval for time-based maintenance activities can be
Maintenance identified.

Safety-related activities, such as fire extinguisher inspections

and smoke alarm tests, are well-suited for time-based
maintenance because the cost of asset failure is high, the
cost of maintenance is very low, and condition-based
maintenance (CBM) is either impossible or costly. HVAC
units, furnaces, and other assets that require seasonal
attention are also great candidates for time-based
maintenance activities.
 How Time- •TBM is implemented by scheduling
regular maintenance tasks, for
Based example, inspections and parts
replacements. TPM is either based on
the manufacturer’s recommendations
Maintenance or historical data. The maintenance
schedule is determined by failure rate
trends, divided into burn-in, useful life,
Works and wear-out phases. These phases
serve as the foundation of TBM and
are illustrated by the bathtub curve
model .
•TBM differs from condition-based
or predictive models that rely on
working equipment’s real-time
conditions. And there are several
proven benefits to using more
advanced models that monitor and
predict the exact time maintenance is
needed with high degrees of accuracy.
•TBM demands routine maintenance,
which can result in over-maintenance
and higher associated costs.
 Fundamentals Implementation
When implementing TBM, a maintenance schedule will be created using historical data or
manufacturer guidelines. It’s important to note that maintenance management software, like
Computerized Maintenance Management System (CMMS+), can help streamline the scheduling,
tracking, and recording of maintenance processes, making a new or existing TBM program much
more efficient.

Implementing Steps to Implement Time-Based Maintenance

TBM
1.Identify equipment suitable for TBM.
2.Establish maintenance intervals based on manufacturer guidelines or historical data.
3.Develop a maintenance schedule and checklist.
4.Train maintenance staff on TBM procedures.
 Best Practices
for Optimizing If We’re looking to improve an existing TBM program, We’re on the
Time-Based right track. The key to improving our maintenance program primarily
lies in refining our existing maintenance management processes. In
Maintenance an industrial setting, everything will revolve around incorporating
continuous assessment, feedback, and documentation into our
processes.
The following best practices can help us optimize TBM. We can
reduce expenses and increase equipment reliability by following the
tips given below.
 Best
Description Impact
Practice

Best Practices Review and Adjustment

of Maintenance
Assess and modify your maintenance
schedule based on real-time equipment
Ensures maintenance activities align
with equipment needs, reducing

for Optimizing Intervals performance and historical failure data. downtime and costs.

Time-Based
Maintenance Incorporate Feedback
from Maintenance Staff
Gain insights from those directly interacting with
the equipment to identify potential
Uses on-the-ground experience to
improve maintenance scheduling and
improvements. Implement valuable feedback. problem identification.

Maintain up-to-date records of all maintenance It makes TBM data-driven, allowing for
Documentation and
activities and analyze them to identify patterns more informed decision-making and
Analysis
and areas of improvement. strategy refinement.

Revisit and refine your TBM program to adapt to Ensures that your TBM program
Continuous
changing conditions and technological remains effective over time by adapting
Improvement
advancements. to new challenges and opportunities.
THANK YOU