Preventive Maintenance of Industrial Equipment: Uptime, Safety and Quality
How to plan, execute and document maintenance to avoid downtime and ensure compliance
A robust equipment maintenance and prevention program not only avoids downtime, it also protects people, safeguards product quality and preserves asset value. At PRO3S, maintenance is embedded into daily operations to ensure availability, precision and regulatory compliance across all lines.
Maintenance and prevention objectives
- Avoid critical failures that may cause accidents, non-conformities or production stops.
- Guarantee process accuracy and repeatability (batch quality, tolerances, calibrations).
- Comply with EHS regulations (ISO 9001, ISO 14001, GMP+, FSSC 22000).
- Extend equipment lifecycle, reducing total cost of ownership (TCO).
- Optimize OEE (Availability, Performance, Quality) through planned stops and standard times.
Maintenance strategy: types and scope
1) Preventive maintenance (time/usage-based)
Scheduled interventions by service hours, cycles or calendar. Includes cleaning, lubrication, adjustments, calibration and wear-part replacement. Benefits: fewer unexpected breakdowns and greater process stability.
2) Predictive maintenance (condition-based)
Action based on actual equipment condition: vibration analysis, thermography, ultrasound, borescope inspections, power-consumption trends. Intervene at the optimal moment.
3) Corrective maintenance
Repair after a failure. At PRO3S we prioritize planned corrective (within stop windows) and minimize unplanned corrective by running a robust preventive plan.
4) Improvement maintenance (kaizen/reliability)
Modifications and standardizations that eliminate root causes of recurrent failures and improve maintainability (accessible lube points, spare kits, dedicated tooling).
PRO3S master maintenance plan
- Asset inventory and criticality (risk matrix for safety/quality/production impact).
- Annual plan and schedule of interventions with stop windows aligned with Production.
- EHS procedures: LOTO lockout/tagout, work permits, potentially explosive atmospheres (ATEX).
- Calibration and metrology of critical instruments with certified standards.
- Spare parts management: minimum stock, per-equipment kits, approved suppliers.
- Training for in-house staff and qualification of external providers.
Documentation, control and traceability
We keep a complete record of every intervention for auditability and continuous improvement:
- Work orders with scope, checklists and consumed spares.
- Per-equipment history (dates, hours, incidents, root causes, corrective actions).
- Electronic checklists and photographic evidence.
- CMMS/ERP integration for real-time KPIs and batch-level traceability.
- Label/QR for direct access to datasheets and maintenance plans on the shop floor.
Operational KPIs for excellence
| Indicator | Description | Target |
|---|---|---|
| MTBF (Mean Time Between Failures) | Average hours between equipment failures | Continuous increase |
| MTTR (Mean Time To Repair) | Average repair time | Progressive reduction |
| % Preventive / Corrective | Maintenance workload balance | > 70% preventive |
| Plan adherence | Preventive work orders completed on time | > 95% |
| Equipment availability | Available time / total time | > 98% (by criticality) |
| Recurrence | Repeat of the same failure | < 3% monthly |
Integrated safety and environment
- Work permits and risk analysis before intervention.
- PPE and task-specific training (electrical, lockout/tagout, confined spaces).
- Waste and oil management in line with regulations.
- Post-maintenance verification (functional tests, technical cleaning, safe release to production).
PRO3S value: operational continuity and certified quality
We combine a qualified in-house team with approved contractors to execute maintenance with industrial discipline, aligned with your production windows and audit requirements. Result: fewer surprises, greater process stability and consistent quality in every batch.
Need to reinforce your maintenance plan or move from corrective to preventive/predictive? We’ll co-design a realistic, measurable roadmap with you.