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48 ISE Magazine | www.iise.org/ISEmagazine The importance of preventive maintenance When it comes to keeping things running smoothly, there are two types of maintenance strategies: proactive and reactive. The reactive, or "if it isn't broken, don't fix it," method is common in many companies, including industrial and manufacturing en- terprises where equipment function is paramount to success. Facility managers often wait until equipment breaks down or problems arise, and then they handle repairs when they're needed. There's also an "if it doesn't look dirty, don't clean it" mindset that does not serve the best interests of the equipment, facility or a company's bottom line. Proactive maintenance takes a different approach and rou- tinely addresses facility concerns and equipment upkeep to prevent major failures or irritating problems. These systematic inspections and processes identify and correct potential prob- lems before they happen. A preventive maintenance program includes regularly scheduled tasks like equipment cleaning, lubrication, oil changes, minor repairs and adjustments, parts inspection and adjustment, or even a complete overhaul or up- grade when needed. We also will discuss preventive mainte- nance for the building itself, which is vital to smooth, efficient operations and productive employees. Why take a preventive approach? A preventive maintenance program is one of the wisest choices a facility manager can make. A detailed program keeps equip- ment operating efficiently; extends the lifetime of physical as- sets; enhances the safety of your employees; keeps the facil- ity comfortable, attractive and energy efficient; and helps you avoid large and costly repairs down the road. If you traditionally take a more reactive approach to mainte- nance and facility management, you could, instead, save your company thousands of dollars by adopting preventive strat- egies. The exact cost savings gained will depend largely on things specific to your company (your industry, the equipment you use, the size of your facility and more). However, it's gen- erally accepted that reactive maintenance will cost you three to four times more than preventive maintenance. Preventive maintenance offers multiple benefits, including reduced downtime, increased equipment efficiency and per- formance, safer working conditions and enhanced company reputation. Every day your facility does not produce or serve customers at optimal levels is a loss to the company. Because you never know when equipment might fail, reactive maintenance re- sults in unplanned downtime, which leads to idle employees, a halt in production and missed deadlines. To get business back up and running as quickly as possible, these unexpected break- downs usually require paying a technician overtime. Some- times the business must cover the high cost of overnighting parts. A preventive maintenance program keeps the disruption of operations to a minimum. An effective program breaks the cycle of downtime and repair. Because maintenance checks are planned, it's easy for you to schedule them in a way that makes the least impact on day-to-day production. In the end, you save valuable time and money by taking proper care of your equipment and keeping everything running smoothly, whether the equipment is related to production, data process- ing or building operation, such as heating-ventilation air con- ditioning (HVAC), lighting, power systems and plumbing. All equipment breaks down due to normal wear and tear. But implementing a preventive maintenance program will keep machines and systems in good working condition while extending their lives. Parts replacement, fluid and oil chang- es and quality inspections make sure everything works as it should. Neglected equipment can use more energy and re- sources than equipment that is running efficiently, and the gains in efficiency could lower your company's power costs. Your facility's performance is enhanced because things break down less often, and small part replacements often re- duce the need for large-scale equipment overhauls. And be- cause the equipment you use isn't cheap, taking better care of it lets you get more hours out of each item, leading to increased profit and decreased costs. Just as increased equipment efficiency and performance are important in the industrial realm, so are safer working condi- tions. The safety of your employees and visitors should be your top priority, and regular preventive maintenance can lead to improved safety and quality conditions for everyone. Routine checks uncover any hazards and prevent unsafe working con- ditions, so you have fewer on-the-job injuries and accidents. These positives can enhance your company's reputation. The day-to-day cost incentives of preventive maintenance might be the biggest reason why facility managers adopt these programs, but your company's reputation will improve, even outside of the corporate walls. Reactive maintenance leads to the negatives of the things listed above: More downtime, lower equipment efficiency and unsafe working conditions, among others. In addition, your company's reputation will suffer if you're consistently putting production on hold or dealing with accident and injury cases, news that often reaches the media. Routine preventive maintenance is necessary for you to keep your company operating at its best. A reliable company that always meets deadlines and keeps employees safe will keep its customers happy, too. And a good reputation is ev- erything. Implementing a preventive maintenance program It will take some time and money initially to set up a program like this, but over the long run your company will see the benefits of regularly scheduled maintenance. W