How to Build a Predictive Maintenance Program from Scratch

A preventative, predictive maintenance program is essential to successful facilities management. Predictive maintenance has been proven to dramatically reduce facilities spend, and its impact extends to customers. Better guest experiences result in repeat purchases and a higher level of customer service. Furthermore, predictive maintenance is getting smarter, and Facilities Managers need to know how to create one from scratch.

Warning Signs That You Need a Predictive Maintenance Program

Companies without a predictive maintenance program may be subject to extreme budget fluctuations and have a marginal hold on facility needs. However, some debate exists between what does and does not constitute a need for predictive maintenance. In other words, some companies follow manufacturer recommendations, but these recommendations often include specific runtimes that are designed for use in ideal operating conditions. Such conditions rarely exist in application, so Facilities Managers need to learn to recognize when a facility needs a predictive maintenance program. Common warning signs of lackluster maintenance programs include:

  • Continued listing of maintenance needs on the maintenance backlog.
  • More needs exist than available funding.
  • Unexpected equipment failure.
  • Higher-than-usual energy costs.
  • Increased field service technician costs.
  • Emergencies, like a fire or electrical shorts, emanating from facility assets.
  • Inability to handle reactive maintenance needs during emergencies.
  • Uncertainty in creating maintenance schedules.
  • Strictly following manufacturer recommendations.
  • Using paper-based systems.
  • Not performing maintenance until “it breaks.”

The Value of a Predictive Maintenance Program is Tangible

As noted in a previous blog post, the value of predictive maintenance is significantly lower than the costs of deferred maintenance. Yet, only 15 percent of Facilities Managers use a predictive maintenance program. However, this statistic is expected to climb as cloud-based solutions and data become more important in identifying when problems may develop and how Facilities Managers can correct the issue before the risk comes to fruition.

How to Create a Predictive Maintenance Plan

Developing a predictive maintenance plan means knowing what to expect and planning for the unexpected by correcting issues before they occur. It sounds confusing, but a modern CMMS uses analytics, which rely on a host of internet-enabled sensors and devices, to evaluate facility and asset health on a frequent basis. In fact, this capability may exist in real-time, allowing for faster, data-based decision making. Of course, creating this data-based program is not so simple, and Facilities Managers should follow these steps to streamline the process:

  1. Get C-Suite support for predictive maintenance by emphasizing ROI and positive effect on guest experiences.
  2. Train your team how to use new systems and meet obligations in the maintenance program.
  3. Automate data collection.
  4. Use the Internet of Things and connected devices to retrofit older facility assets and monitor the environment.
  5. Deploy analytics to manage data, and integrate systems, explains Facility Executive.
  6. Make data actionable by using it in making maintenance decisions.
  7. Prioritize the maintenance schedule to reflect data.
  8. Keep sustainable business practices, like lowering energy consumption and reducing waste, in mind.
  9. Consider outsourcing predictive, preventative maintenance to a third-party, capable of handling work orders across your portfolio.

Kickstart Your Predictive Maintenance Program with a Shot of Energy From QSI Today

A predictive, preventative maintenance program is much more than just following manufacturer recommendations for maintenance. An effective program must identify strengths and weaknesses in assets, create a plan for eliminating the maintenance backlog, and use information to endure maximum ROI. Following the aforementioned tips will allow your organization to get started developing a preventative maintenance program, and don't forget to contact QSI Facilities today.

QSI Facilities

QSI Facilities