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            COMPLETE GUIDE: PREVENTIVE MAINTENANCE
                        by FreeMaint
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                         TABLE OF CONTENTS

1. What is preventive maintenance?
2. Types of preventive maintenance
3. Benefits of preventive maintenance
4. How to set up a preventive maintenance program
5. Industry-specific plan examples
6. Key Performance Indicators (KPIs)
7. Recommended tools

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1. WHAT IS PREVENTIVE MAINTENANCE?
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Preventive maintenance involves performing planned interventions on
equipment BEFORE a failure occurs, unlike corrective maintenance which
intervenes AFTER the breakdown.

Objectives:
- Reduce unexpected breakdowns (up to 70% reduction)
- Extend equipment lifespan
- Optimize maintenance costs
- Improve safety
- Increase machine availability

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2. TYPES OF PREVENTIVE MAINTENANCE
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A. TIME-BASED MAINTENANCE
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Interventions at regular intervals (time or cycles).
Example: Oil change every 10,000 km or 1 year

B. CONDITION-BASED MAINTENANCE
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Interventions based on the actual condition of the equipment.
Example: Replacing a bearing when vibrations exceed a threshold

C. PREDICTIVE MAINTENANCE
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Using sensors and data analysis to predict failures.
Example: Oil analysis, thermography, vibration analysis

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3. BENEFITS OF PREVENTIVE MAINTENANCE
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+----------------------------------+----------------------------------+
| CORRECTIVE MAINTENANCE           | PREVENTIVE MAINTENANCE           |
+----------------------------------+----------------------------------+
| Emergency interventions          | Planned interventions            |
| Unexpected production stops      | Scheduled, controlled stops      |
| High costs (parts + emergency)   | Optimized costs                  |
| Increased safety risks           | Improved safety                  |
| Short equipment lifespan         | Extended lifespan                |
| No visibility                    | Planning and forecasting         |
+----------------------------------+----------------------------------+

Typical ROI: 3 to 10 times the cost of the preventive maintenance program

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4. HOW TO SET UP A PROGRAM
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STEP 1: INVENTORY YOUR EQUIPMENT
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- List all critical equipment
- Collect technical specifications
- Identify wear-prone components
- Define criticality (impact of failure on production)

STEP 2: DEFINE INTERVENTION FREQUENCIES
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- Consult manufacturer recommendations
- Analyze breakdown history
- Consider operating conditions
- Adjust based on field experience

STEP 3: CREATE MAINTENANCE ROUTINES
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- Describe each task in detail
- Specify required tools and parts
- Estimate intervention time
- Define required skills

STEP 4: PLAN AND MONITOR
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- Use a CMMS to plan interventions
- Generate work orders automatically
- Track execution in real time
- Analyze results and adjust

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5. INDUSTRY-SPECIFIC PLAN EXAMPLES
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MANUFACTURING
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Equipment: Hydraulic press
- Daily: Check oil level, visual inspection
- Weekly: Clean filters, check pressures
- Monthly: Lubrication, check alignment
- Annual: Change hydraulic oil, check seals

FACILITY MANAGEMENT
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Equipment: HVAC unit
- Monthly: Clean filters, check temperatures
- Quarterly: Check seals, clean evaporator
- Annual: Refrigerant check, electrical inspection

HOSPITALITY
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Equipment: Elevator
- Daily: Check general operation
- Monthly: Clean cabin, check lighting
- Annual: Mandatory regulatory inspection

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6. KEY PERFORMANCE INDICATORS (KPIs)
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MTBF - Mean Time Between Failures
The higher, the better.

MTTR - Mean Time To Repair
The lower, the better.

Availability Rate = (Operating Time / Total Time) x 100
Target: > 95%

Preventive/Corrective Ratio = (Preventive Interventions / Total) x 100
Target: > 70% preventive

Maintenance Cost per Equipment
Track to optimize investments.

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7. RECOMMENDED TOOLS
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For effective preventive maintenance management, a CMMS is essential.
It allows you to:

- Automatically schedule interventions
- Generate work orders
- Track execution in real time
- Manage spare parts
- Analyze KPIs
- Record all intervention history

FREEMAINT - 100% FREE CMMS
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FreeMaint offers all these features for free:
- Automated preventive maintenance
- Mobile app for technicians
- Dashboards and reports
- Unlimited users
- No credit card required

Get started now: https://freemaint.com

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                         freemaint.com | 2026
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