What is Industrial Maintenance? Common Types of Industrial Maintenance Methods

In the context of rapid industrialization and modernization, maintenance activities play a crucial role alongside the implementation and operation of systems. They contribute to ensuring stable, safe, and efficient production activities. So, what is industrial maintenance, and what are the common industrial maintenance methods today? Let’s explore with INTECH Service in this article!

What is Industrial Maintenance?

According to Wikipedia, maintenance is defined as the activities related to inspecting, maintaining, repairing, or replacing equipment, machinery, building infrastructure, and supporting utilities in industrial, commercial, and residential projects. The subjects of industrial maintenance include all equipment, machinery, systems, and other infrastructure within a factory/workshop.

This process ensures that machinery, equipment, and facilities in factories operate stably and optimally, minimizing the occurrence of breakdowns that interrupt production.

industrial maitenance

Benefits of Proper and Timely Industrial Maintenance

  • Easily Pass ISO, GMP, HACCP Audits
  • Control Situations and Minimize Facility Damage
  • Timely Detection and Repair of Operational Errors
  • Minimize Production Interruptions and Economic Losses
  • Optimize Plant Capacity and Output
  • Reduce Defective Products, Ensuring Consistent Quality
  • Maximize Cost Savings on Repairs and Extend System Lifespan
  • Ensure Production Safety and Worker Safety

Benefits of industrial maintenance

Types of Common Industrial Maintenance Methods

Corrective Maintenance

Corrective Maintenance is performed after equipment or systems have failed or encountered an issue. The goal is to repair or replace faulty parts to restore functionality.

maintenance and recovery

Advantages of Corrective Maintenance:

Simple and Easy to Implement: It does not require extensive technical knowledge or high expertise, nor does it need significant investment in advanced equipment or technology.

advantages of maintenance and recovery

Lower Initial Costs: Compared to other advanced maintenance methods, corrective maintenance has lower initial costs, with no need for monitoring equipment or data analysis software.

Flexible: This method can be carried out whenever equipment fails without prior planning, making it suitable for emergencies or situations where resources are limited.

Disadvantages of Corrective Maintenance:

High Repair Costs: Repairing equipment post-failure is often more expensive than preventive maintenance. The costs of replacing parts, labor, and downtime can significantly impact the budget.

disadvantages of maintenance and recovery

Impact on Production: Equipment failure leads to production halts, resulting in revenue loss, material waste, and increased production costs.

Challenges in Cost Management and Budget Forecasting: Unpredictable equipment failures make it difficult for businesses to budget and forecast maintenance costs accurately.

Preventive Maintenance

Preventive Maintenance is a proactive maintenance method aimed at preventing machinery and equipment failures before they impact production activities.

preventive maintenance

Instead of waiting for machinery to break down before repairing it, preventive maintenance focuses on early detection of potential issues and timely intervention to avoid operational disruptions and save on repair costs.

Advantages of Preventive Maintenance:

Minimize Downtime Due to Breakdowns: Preventive maintenance helps identify and address potential problems early, reducing machine and equipment downtime and optimizing production efficiency.

Save on Repair Costs: Early detection of potential issues allows for timely repairs, preventing severe damage and thus reducing repair costs.

Extend Machinery Lifespan: Regular maintenance ensures machinery operates more reliably and extends its usable life, minimizing the need for new equipment investment.

Increase Production Capacity: Keeping machinery in good working condition enhances production capacity, meeting market demands and increasing business profitability.

advantages of preventive maintenance

Improve Product Quality: Preventive maintenance ensures machinery operates accurately and stably, improving product quality and reducing the defect rate.

Enhance Business Reliability: Ensuring stable equipment operation minimizes downtime, allowing businesses to manage production operations proactively, improving efficiency and reputation in production activities.

Disadvantages of Preventive Maintenance:

High Initial Budget and Costs: The initial implementation cost of preventive maintenance is higher compared to other methods due to the need to invest in the latest tools and equipment for maintenance work, increasing overall business expenses.

Requires More Resources and Manpower: Preventive maintenance demands more maintenance personnel due to frequent inspections and checks.

disadvantages of preventive maintenance

Predictive Maintenance

Predictive Maintenance is a proactive maintenance strategy that uses advanced technologies such as sensors, data analytics, and artificial intelligence to predict when machinery and equipment might fail before a breakdown occurs.

By knowing when a part is likely to fail, maintenance managers can plan maintenance activities only when necessary, avoiding over-maintenance and preventing unexpected equipment failures.

predictive maintenance

Advantages of Predictive Maintenance:

Proactively Prevent Failures: The key difference with predictive maintenance is its ability to accurately predict when machinery and equipment are at risk of failure, allowing for proactive maintenance planning suited to the business’s specific conditions.

Optimize Resources and Save Costs: Businesses can focus maintenance efforts only when truly needed, avoiding the waste of resources, materials, and time on inefficient periodic maintenance activities.

advantages of predictive maintenance

High Accuracy: Predictive maintenance uses collected data to forecast maintenance needs, resulting in more accurate outcomes compared to other methods.

Flexibility: Predictive maintenance allows businesses to adjust maintenance plans based on collected data, providing greater flexibility in managing maintenance activities.

Disadvantages of Predictive Maintenance:

High Initial Investment Costs: Implementing a predictive maintenance system requires significant initial investment in hardware, software, staff training, and establishing the necessary infrastructure.

disadvantages of predictive maintenance

Data Dependency: The effectiveness of predictive maintenance heavily depends on the quality and accuracy of data collected from sensors and monitoring devices. Incomplete, inaccurate, or inconsistent data can lead to incorrect diagnostics and ineffective predictions, affecting maintenance planning and posing potential risks.

Limited Applicability: Predictive maintenance is not effective for all types of equipment and machinery. Some older or simpler equipment may not support sensor installation or comprehensive data collection, limiting the application of this method.

Reputable and Professional Industrial Maintenance Service Provider

With many years of experience in industrial maintenance, having implemented numerous large-scale projects for factories and workshops, and backed by a team of highly skilled engineers and technicians, INTECH Service is committed to providing reputable and professional industrial maintenance services of the highest quality at the most reasonable and optimal prices for customers. Contact INTECH Service today to receive the earliest consultation!