It is very important to know the difference between predictive, preventive and corrective maintenance and, in addition, when to use each of them.
A company, when working with the provision of services, cannot but pay special attention to maintenance.
The idea is to save and reduce costs, so that your company spends only on good investments and not on errors that can be foreseen. The frequent monitoring of the operation of machines, equipment and parts is a very effective method to avoid possible interruptions in production lines. Thus, it is possible to realize the importance of maintenance management. And for this to happen effectively, it is necessary to understand the difference between predictive, preventive, and corrective maintenance.
• ▶ Planned Maintenance, subdivided into predictive, preventive and corrective maintenance;
• ▶ Unplanned maintenance.
Predictive maintenance is the periodic monitoring of equipment or machines, using data collected through inspections. The most common techniques used for predictive maintenance can be: vibration analysis, ultrasound, visual inspection and other non-destructive analysis techniques. It is a process that counts the useful life of the components of the machines and equipment and the conditions for this lifespan to be well used. It can be compared to an inspection to monitor the condition of the equipment. The objectives for doing predictive maintenance are:
• ▶ Determine, in advance, the need to maintain a part, tool, or machine;
• ▶ Eliminate unnecessary disassembly for inspection;
• ▶ Increase the durability of equipment;
• ▶ Reduce unplanned emergency work;
• ▶ Avoid additional damage.
Through these objectives, it is possible to conclude that predictive maintenance has a greater purpose: to reduce maintenance costs and increase employee productivity.
Preventive maintenance has as its main objective the prevention of a breakdown or breakage in the equipment, in addition to reducing the wear speed of the machines and appliances. It is, therefore, an intervention planned, prepared and programmed before the appearance of a problem.
Preventive maintenance services must be planned and programmed, that is, all stages of the service to be performed must be well defined. Some examples of preventive maintenance are:
• ▶ Periodic lubrications;
• ▶ Systematic equipment reviews;
• ▶ Instrument calibration and measurement plans;
• ▶ Equipment inspection plans;
• ▶ The manufacturer's histories or recommendations. Preventive maintenance can also be performed depending on the condition of the equipment, such as repairing defects, renovations, or overhauling.
As its name says, it serves to correct a flaw. Corrective maintenance happens when the equipment is already left with irregular parts, malfunctions, and has to be replaced. This maintenance may be necessary in two situations: when an unexpected fault occurs, or when a fault is detected that could lead to a major problem in the future. Therefore, we can divide corrective maintenance into two subtypes: planned and unplanned correction. Planned corrective maintenance is nothing more than monitoring a machine in order to correct any error that will appear. Everything here is planned. Unplanned corrective maintenance happens after an error or problem has been identified. This type of maintenance involves high costs compared to planned corrective maintenance. However, corrective maintenance can also be used as an efficient way to avoid rework, after all, it decreases task execution time and prevents unexpected production breaks.
We know that corrective maintenance is normally performed after a failure or productive incapacity of an equipment or facility. A significant percentage of these damages can be prevented if the maintenance manager takes into account the preventive maintenance of this equipment. Corrective maintenance has a greater financial impact than preventive maintenance. Since it may entail the prolonged suspension of the activity of the machinery and equipment, it may even lead to the unavailability of a production line or other service. The main advantage of having a preventive maintenance plan is being able to prevent all these situations, replacing the components used within the right time, preserving and restoring all the necessary parts. To do this, the manager must organize in a spreadsheet, or other tool, the main metrics and information he needs to track in order to carry out major planning:
• ▶ Improve the technical and operational state of the equipment;
• ▶ Reduce degradation and the risks of equipment degradation;
• ▶ Work to prevent schedules;
• ▶ Perform repairs under conditions favorable to operation;
• ▶ Reduce costs;
• ▶ Extend the lifespan of the equipment.
A preventive maintenance plan is ideal when the maintenance manager can prevent any defect in your equipment, or can predict and schedule so that this failure has the least possible impact on the customer.
Preventive maintenance, as we have said, is planned and takes place within a predetermined time, allows the early identification of problems, reduces expenditure requirements and allows for better budget planning. Predictive maintenance programs are based on the actual condition of the equipment and the determination of when maintenance should be performed to minimize costs.
The problem with relying solely on corrective maintenance is that, with the equipment or vehicle damaged, the company will stop making profits as long as it remains inactive for repairs. Predictive maintenance comes to prevent this, along with preventive maintenance. It will show the technician where the fault is or where it may occur specifically, because it uses techniques such as ultrasound, vibration analysis, and others, as mentioned earlier. When maintenance management is clearly done, the work will be a little more intense for everyone, but the results will certainly be improved. In the end, predictive, preventive, and corrective maintenance are essential for the execution of good work by both the team and the manager.
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