The 6 Types of Maintenance: Definitions, Benefits, Examples

Maintenance is the process of keeping equipment, machinery buildings, or systems in a

good working condition through regular inspection, servicing, repair, or replacement of
part. In another word, can be defined to a set of processes and practices which aim to ensure
the continues and efficient operation of machinery/equipment and other types of assets
typically use in businesses. Workshops/studios and laboratories.

Different Types of Maintenance

There are six general types of maintenance strategies that companies/organizations use.
They are a range of proactive and reactive methodologies. Depending on how you form
your business structure, maintenance can become costly or affordable, create problems or
solve them. Part of why the right maintenance program is important is how you manage
them, the impact on customers, and the total cost based on the investment return.

Types of Maintenance

The different types of maintenance strategies include:

➢ Preventive maintenance – includes regular and periodic (time-based) schedules.

➢ Corrective maintenance – occurs when an issue is noticed.
➢ Predetermined maintenance – follows a factory schedule.
➢ Condition-based maintenance – occurs when a situation or condition indicates
maintenance is needed.
➢ Predictive maintenance – is data-driven and impacted by preset parameters.
➢ Emergency (Reactive) maintenance – occurs when a total breakdown or failure
appears immediately.

The 6 Types of Maintenance: Overview

1. Preventive Maintenance (Routine)

This type, preventive maintenance, seeks out and repairs more minor issues and decreases
the occurrence of major repairs. Preventive maintenance may take on aspects of all other
maintenance types.

For example, maintenance inspections may change based on the age of the equipment.
When it is new, the procedure may be more of a predetermined maintenance style, but as
it ages, more frequent inspections, both physical and through data. This will prevent more
minor performance issues from becoming extensive and costlier repairs.

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The Right Maintenance Strategy Reduces Risks, Improves Efficiency and Extends the Life
of Your Assets

Example of Preventative Maintenance

An excellent example of preventative maintenance is the seasonal cleaning of an HVAC

unit. In spring, you schedule maintenance to ensure that grit and sand are not inside the
casing or leaves are not blocking the air intake in the fall. There is no specific issue, but we
know that leaves can accumulate and cause problems later in the fall. Removing the grit or
leaves now prevents a later difficulty, such as poor performance, increased energy usage,
etc.

Preventive maintenance is easily described as regular and routine inspections that look for
wear before symptoms appear.

Costs of Preventative Maintenance

Expect to pay more for labour under preventative maintenance, so equipment inspections
occur as scheduled. However, those added labour costs may be offset by preventing major
repairs and therefore increasing in energy consumption from machines that do not operate
at peak performance. In addition, service can be outsourced, which can help reduce the cost
of labour.

Advantages/Benefits of Preventative Maintenance

➢ It Prevents major repairs by Reduces unexpected breakdowns.

➢ It Keeps businesses open by preventing most emergency repairs.
➢ It Extends equipment life by Adding product’s lifecycle and reducing wear.
➢ It Keeps energy costs at their lowest possible rates.

Disadvantages:
➢ May result in unnecessary maintenance.
➢ Requires scheduling and planning.

2. Corrective Maintenance

Performed after a fault is detected to restore equipment to proper working condition.

Maintenance teams activate after the uncovering of a problem. The goal of corrective
maintenance is to bring systems back to regular operation as quickly as possible. With
corrective maintenance, there is no program for regular maintenance. A problem must be
present before maintenance occurs.
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Examples of corrective maintenance include:
Repairing a broken unit rather than maintaining it.
Repairing a broken conveyor belt in a factory.
Repairing unit after data from the unit shows it is not functioning at peak performance.

Cost of Corrective Maintenance

Because there is not a regular maintenance program that prevents breakdown, maintenance
occurs only when an issue is noticed. The cost of repairs may be slightly more expensive
but far cheaper than paying maintenance to maintain equipment. The driving force is fixed
just in time, but that can backfire if a catastrophic event happens. In the above example, if
a unit is not repairable, then replacement is the only option. Even then, some costs for
replacement may be covered by a warranty.

Advantage/Benefits of Corrective Maintenance

➢ Decreased monthly maintenance costs by lower initial cost (no upfront planning).
➢ Decrease in time for managing maintenance.
➢ Focuses on non-critical elements.
➢ A Simple more straightforward maintenance process.

Disadvantages:
➢ Unplanned downtime.
➢ May result in higher repair costs and production loss.

3. Predetermined Maintenance (Planned)

Predetermined maintenance follows a plan of action created by the manufacture of

equipment, rather than scheduled maintenance laid out by a maintenance team.
Maintenance scheduled in advance, regardless of equipment condition.

Examples of Predetermined Maintenance

An excellent example of predetermined maintenance is when machinery maintenance is

scheduled at time intervals based on the manufacture’s recommendations. For example, oil
changes will be every fourth month. Transmission service will occur at X number of hours
of run time. After one year of use, Parts X, Y, and Z are checked for wear. Engine
replacement occurs after X number of years.
Even if the machine has sat idle for four months, the oil is changed. The list of maintenance
is scheduled based on time or usage rather than functionality.

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Another example is when smart data indicates a decrease in productivity. The drop in
performance signals a need for maintenance. Predetermined maintenance crosses over into
predictive maintenance, where data reporting for issues occurs.

Extend the Life of Your Assets

Cost of Predetermined Maintenance

The cost of predetermined maintenance programs is generally low. Because everything is

scheduled, you can plan for part or service items for maintenance. Costs do vary based on
the machinery and parts associated, but even those are known costs.

Advantages/ Benefits of Predetermined Maintenance

➢ Much easier to schedule and manage, including labor.

➢ The manufacturer outlines the maintenance plan.
➢ Reduces unexpected failures.
➢ Easy to plan resources.
➢ You can schedule technicians rather than hire maintenance personnel.

Disadvantages:
➢ May not align with actual equipment needs.
➢ Potential for over-maintenance.

4. Condition-Based Maintenance

As the name implies, condition-based maintenance focuses on outcomes through

measurement or observation. Machines have a range of normal operating conditions.
Within that range, the operation is acceptable. Near the edges of that range, maintenance
may be required.

Examples of Condition-Based Maintenance

An excellent example of condition-based maintenance is that pesky check engine light in

your car. When it comes to the car’s system has indicated that something is out of the
normal range and maintenance is scheduled. The exact process may occur with machines
that self-monitor through smart technology or physical inspections in a business.

Another example of condition-based maintenance might be when a machine begins to use

more energy to function. That may be that a tank of fuel does not last as long or that there
is a sudden spike in electrical usage. Again, that level of condition requires maintenance.

Cost of Condition-Based Maintenance

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The overall cost of condition-based maintenance is low. It is a function of the condition of
equipment over time and before a failure occurs. It is also known as a P-F curve. Because
maintenance is scheduled when anomalies begin, the cost to correct them is less than
repairing a complete failure of the machine. The benefits of Conditional-based
maintenance show us more.

Advantages/Benefits of Condition-Based Maintenance

➢ Decreased energy consumption.

➢ Greater productivity — the equipment runs in the range of peak performance for
longer.
➢ Fewer complete failures as equipment maintenance occur as the performance drops.
➢ Efficient use of resources.
➢ Avoids unnecessary maintenance.

Disadvantages:
➢ Needs constant monitoring.
➢ Can be complex to implement.

5. Predictive Maintenance

One of the more advanced ways that maintenance occurs is based on the condition of
equipment, using data and monitoring tools, predictive maintenance, is data-driven. Data
supplied by the equipment indicates when maintenance occurs. Data also is a means to map
when the failure of the machine may occur.

Examples of Predictive Maintenance

Technology is all around us, and many businesses put it to work for them. The examples
of predictive maintenance would include:

Alarms that sound when the temperature on a machine or in an environment begin to move
outside the safe parameters set up per the manufacturer’s guidelines. The enteral
temperature in a data center’s server room becomes too hot, and sensors in that room alter
maintenance.

A sensor in an engine monitors misfires and alerts maintenance that engine service is
needed.

A sensor on a refrigeration truck monitors the enteral temperatures of the truck and alerts
the driver when the internal temperature falls outside acceptable parameters.

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These alerts do not necessarily mean a complete failure occurs, but that condition is
approaching a range where catastrophic failure can occur.

Advantages/Benefits of Predictive Maintenance

➢ There is a higher cost at set up for predictive infrastructure, but overall, predictive
maintenance can save money by:
✓ Improving product quality.
✓ Reducing catastrophic failures.
✓ Improved equipment performance.
✓ Higher customer satisfaction.
➢ There can also be a reduction in maintenance labor since automation can also
become part of the predictive process.
➢ data driven predictive maintenance
➢ Cost-effective by addressing issues before failure.
➢ Minimizes downtime.

Disadvantages:
➢ Requires specialized tools and training.
➢ Higher initial investment.

6. Emergency/Reactive (Run-to-Failure) Maintenance

Reactive maintenance is a maintenance system that responds when a failure of machinery

or systems occurs. The repairs may be handled in-house or by the manufacturer, or through
a combination of in-house maintenance and the manufacture’s technicians. Urgent repair
done when equipment fails unexpectedly.

Unlike preventive maintenance, reaction maintenance occurs when a breakdown happens.

Reactive maintenance implies fix when broken, Emergency fix now because the condition
is critical
All emergency maintenance is reactive, but not all reactive maintenance is an emergency.

Examples of Reactive Maintenance

The car wash at the local gas station breaks, and the maintenance team is notified. The
printing press that handles varnish applications fails, and maintenance or the factory service
team is notified, and repairs are scheduled.
Fixing a burst pipe in a factory.

Costs of Reactive Maintenance

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The costs of reactive maintenance can range from minor repairs to total replacement of
machinery. Therefore, it becomes difficult to predict the cost of reactive maintenance,
though occasionally the cost is offset by a warranty or service contract.
Maintenance Management Based on Actionable and Data-Driven Insights
Managing maintenance across an entire fleet is quite a challenge. Build custom workflows
in our Asset Operations Platform to easily manage maintenance processes for thousands of
assets.

Advantages/Benefits of Reactive Maintenance

It may seem like a waste of money to not have any other type of maintenance in place
before machinery or equipment fails. However, there are some cost savings associated with
Reactive Maintenance. Those include:

➢ Less maintenance staff, fewer employees, fewer wages paid out regularly, etc.
➢ Fewer costs to implementation – No regular maintenance means no labor or part
costs until failure occurs.
➢ Fewer management hours are needed for maintenance planning.
➢ Restores operation quickly.
➢ Necessary for critical failures.

Disadvantages:
➢ High cost and downtime.
➢ Disrupts planned operations.

How to Choose the Right Strategy?

Choosing the best maintenance methodology is a measurement of risk. First, look at what
you lose if equipment fails. If the cost is greater than the repair, then a reactive type
maintenance methodology may be perfect for your businesses. On the other hand, if the
cost is higher if machinery fails, then a proactive type of maintenance methodology might
be more beneficial.

Weigh in aspects such as:

Time for maintenance to occur.
Cost to business in terms of loss of production.
Ask yourself: are customers impacted?
A business may also need more than one type of maintenance, depending on the nature of
what they do. For example, preventative maintenance is an asset if it protects measurements
such as customer satisfaction, reduces legal risks, etc. On the other hand, reactive
maintenance may be more economical if the equipment is under warranty or approaching

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the end of its lifecycle. Regardless of which strategy you choose, maintenance management
software can help your company automate tasks, maintain an overview and be more cost-
effective.

Why Is the Right Maintenance Strategy Important?

The right maintenance strategy is crucial because it reduces risks and improves efficiency
while keeping costs in an affordable range. You also have the opportunity to extend the life
of your assets. That process also means reducing the cost of repairs and keeping overall
productivity higher.

What Are the Different Types of Maintenance?

The 6 different types are; Predetermined Maintenance, Preventive Maintenance, Corrective

Maintenance, Condition-based Maintenance, Predictive Maintenance and Reactive
Maintenance.

How to Choose the Right Maintenance Strategy?

Choosing the best maintenance methodology is a risk measurement. Start by looking at

what you lose when equipment fails. If the cost is higher than the repair cost, then a reactive
maintenance method may be ideal for your business. On the other hand, if the costs are
higher in the event of a machine failure, then a proactive maintenance method might be
more beneficial.

What Are the 4 Types of Computer/Software Maintenance?

The 4 different software maintenance types are; Corrective Software Maintenance,

Adaptive Software Maintenance, Perfective Software Maintenance and Preventive
Software Maintenance.

Why Is the Right Maintenance Strategy Important?

The right maintenance strategy is critical because it reduces risks and improves efficiency
while keeping costs within an affordable range. You also have the opportunity to extend
the life of your equipment. This process also means that the cost of repairs is reduced and
overall productivity remains higher.