How Much is too Much Preventive Maintenance?

Preventive maintenance is the performance of maintenance activities that are designed to prevent a piece of equipment from failing. It is a recognized fact that the costs of repairing a piece of equipment that fails unexpectedly are substantially higher than the costs of maintenance tasks to keep equipment running smoothly. In addition, there is potential production loss caused by unplanned downtime when a piece of equipment fails, which can be extremely costly.

Preventive maintenance strategies are based on time or usage. Maintenance intervals are set based on calendar time or meter run count since the last activity. Once this time or meter threshold is crossed, an automatic maintenance event is triggered and the task is executed. If a piece of equipment fails unexpectedly, the preventive maintenance interval may be reduced and the maintenance workload will keep increasing, even if the failure was not directly related to preventive maintenance. Many companies are giving thoughtful consideration to their strategies for preventive maintenance in order to optimize their resources and improve their maintenance performance.

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  • Nov 02, 2016

    Why DPSI?
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    DPSI offers industry leading EAM and CMMS solutions that has been the system of choice for more than 6,000 customers and 50,000 users since 1986. The solutions are scalable to any size organization, from a single site to corporate world-wide manufacturing, facility and fleet organizations. Its products and service have helped customers reduce maintenance costs, increase safety, reliability and product quality, decrease downtime and extend the operational life of equipment.


    iMaint is DPSI’s EAM (Enterprise Asset Management) solution. Central to the system is the establishment of Assets and related information. The core component of iMaint is the work order module. Orders can be scheduled manually or automatically – using a variety of schedules or other input criteria. Added documentation like procedures, drawings and parts lists can be configured to be attached to the work order when it is issued. Completing and closing these orders provides relevant data for analysis.

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  • Sep 23, 2016

    What is Maintenance Workflow?
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    Workflow is the step-by-step process that gets initiated by some trigger event to the point where the action is closed out. For example, in a typical maintenance operation, a trigger event could be a report of faulty equipment. The step-by-step workflow process would include the generation of a maintenance order, the planning of the task, the execution of the repair and the reporting at the end of the job. Every organization has a workflow process whether it is officially documented or not and there is always a standard way to get things done. When this process is not well-defined, it can lead to frustrations on the part of employees trying to get their job done and there can be major inefficiencies that are costly to the organization over time.

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  • Sep 19, 2016

    Selecting the best CMMS
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    Which one is right for you?

    The journey towards selecting the best CMMS system for your business or organization begins with defining clearly the objectives you are hoping to achieve through the implementation of a CMMS. The most common reasons for implementing a CMMS system are:

    • Improved asset reliability and safety
    • Reduction of maintenance costs
    • Access to current technology such as Cloud, Mobile, and real-time Dashboards
    • Integration with other business applications

    CMMS system

    It is a good idea for any organization to put together a CMMS selection and implementation team to work through the selection criteria. This enables representatives from management, maintenance, operations and accounting functions to work together and determine the critical requirements for the CMMS system that will be used to evaluate competitive products. Consider questions like:

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  • Sep 12, 2016

    5 Ways to Reduce Maintenance Management Costs
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    Reducing the maintenance management costs of a facility while at the same time maintaining a high level of reliability and availability is a finely-tuned balancing act. Here are some tips for reducing expenses without compromising on production.

    1. Organizations that are good at keeping maintenance management costs under control generally place a high priority on learning and continuous improvement. Techniques like RootFacility Maintenance Cause Analysis are used to determine the reasons for failure and appropriate corrective actions along with Reliability Centered Maintenance. This is done in order to develop the best maintenance strategy to prevent equipment failure while improving maintenance performance. These organizations are never satisfied with the status quo; there is always something that can be done to lift the performance to an even higher level.

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  • Sep 06, 2016

    What is Root Cause Analysis and why should you care?
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    Preventive Maintenance ProgramOne of the main ways for manufacturing companies to reduce costs and improve production capacity is by investigating the cause of equipment failures and implementing corrective actions to prevent future failures. A well-known industry standard method for investigating failures is Root Cause Analysis. With Root Cause Analysis, the principle question being asked is, “What is the fundamental reason that caused this equipment to fail?” Once this basic cause is identified, action can be taken to ensure that there is no repeat of the same failure.

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  • Sep 01, 2016

    Identifying Problem Assets
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    A problem Asset can be defined as a piece of equipment that has had a significant negative impact on the manufacturing process. This definition includes:

    • Equipment that has a low MTBF (mean time between failures). This means the equipment fails more regularly than expected.
    • Equipment that has a very high annual maintenance cost. This data is easily accessible from a CMMS system where cost per equipment can be viewed as a standard report or graph.
    • Equipment that has caused production downtime.
    • Equipment that has failed shortly after its last repair.


    IiMaint softwaren order to identify the problem Asset list and resolve issues, it is necessary to rank each piece of equipment based on the total cost of failure. This is done by adding the maintenance repair cost to the loss of production value to calculate a total cost of the impact of failure. The “worst” Asset is the one which has the highest total cost of impact. Normally, the loss associated with lower production far outweighs the individual cost of a repair.

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  • Aug 26, 2016

    5 Spare Part Management Tips
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    Spare Part ManagementSpare parts management can be a nightmare of holdups, downtime and loss of production or a smoothly running system that supports maintenance activities efficiently, keeps the plant running and production on target. Here are 5 tips to optimize your spare parts management process.

    1. 1.Use CMMS trends to set reorder levels. Spare parts management is a balance between making sure that you don’t stock out of a critical part while at the same time keeping your inventory value as low as possible. Keeping inventory low minimizes the monetary value held up in stock and frees up cash flow for other activities. Analyzing trends with your CMMS software for high usage spares can help you to set an optimum reorder point. The reorder point must allow sufficient lead time for new stock to arrive before the existing stock runs out.

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  • Aug 16, 2016

    How to Maximize the Value of Data from your CMMS Software
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    CMMS SoftwareSuccessfully implementing computerized maintenance management software requires a sizable investment, time for implementation and training, and ongoing effort to ensure that it functions optimally. Given the human and financial capital required to implement and maintain CMMS software, every organization wants to see it utilized to its full capacity. The following guidelines for maximizing the value of your data will help you achieve the best results with your maintenance software.

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  • May 04, 2016

    Is it Time to Change your CMMS Software?
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    Change your CMMS Software

    Purchasing computerized maintenance management software is a significant investment for any company, and moving to a new system can be very time-consuming. For this reason, most organizations are content with upgrading their existing maintenance software instead of switching to a new system.

    Nevertheless, you should regularly assess your CMMS system and its performance. Furthermore, since CMMS systems have evolved over the last few years, it might be worthwhile for your company to research other CMMS software vendors and compare their features and pricing options. The following are signs that it might be time to upgrade to a new CMMS altogether.

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  • Apr 27, 2016

    10 Important Capabilities of CMMS Software
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    Capabilities of CMMS Software

    CMMS software is an incredibly valuable tool for organizations that perform maintenance across various industries.If maintenance software is properly set up and integrated into an organization’s operations, the benefits are remarkable. The following are 10 important capabilities of CMMS software.

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