The document discusses key aspects of effective maintenance management, including defining goals, developing strategies and plans, creating schedules, and allocating resources. It emphasizes that maintenance should be viewed as a business that supports organizational goals and profitability. Effective maintenance management requires considering maintenance a strategic investment rather than just an expense.

1. EFFECTIVE MAINTENANCE
MANAGEMENT
INTRODUCTION
Maintenance Management is the process of coordinating various maintenance
activities and resources for effective asset management and reliability. It
involves the effective utilisation of resources to achieve the company’s objective
in terms of asset reliability. Effective maintenance management is not just
ensuring asset reliability. It stretches into ensuring that asset utilisation and
reliability has a significant impact on the company’s fortunes.
For effective maintenance management, the following must be in place:
1. Goal
2. Strategy
3. Plan
4. Schedule
5. Resources
THE GOAL OF MAINTENANCE.
The goals that we want to achieve in equipment maintenance need to be defined
and outlined. What are our objectives when carrying out a maintenance activity?
Equipment reliability would be the most likely and of course most reasonable
answer. We want to ensure that we get at least a positive return on what was
invested in acquiring the asset. Most maintenance professionals don’t think that
far. For a lot of us, the asset is like a baby we cradle to old age, and we have a
sense of accomplishment when we look at what we have maintained for twenty
or more years still in good condition. That’s great, but the investor is looking at
the numbers. Has the investment made yielded the desired return? Maintenance
management is not effective if that question can’t be given a positive answer. It
is very necessary to ensure that the goal of maintenance is aligned with the goal
of the business making the investment not just in equipment but also in funding
the maintenance activities.
Maintenance management does not just stop at ensuring equipment reliability.
Maintenance management ensures that its activities are being carried out to

2. fulfil the goals of the business. The assets are managed in a way that it furthers
the prosperity of the investor. Decisions made for acquisition, refurbishment,
replacement, or even simple oil change are done with the success of the
business in mind.
This is becoming imperative in this age of cost cutting, outsourcing being on the
front burners of most business owners. Competition is getting fiercer and global
disruptions are becoming annual events. While it is very necessary to ensure
that new cutting-edge technology is deployed for work to be done smartly,
justifications need to be made and the value added needs to be seen.
MAINTENANCE STRATEGY.
Having the goals and objectives clearly defined makes it easy to deploy the right
maintenance strategy. One major outcome of the strategy is establishing a
corporate maintenance policy. A maintenance policy is important to ensure that
the necessary maintenance activities are carried out in a consistent, organized,
and cost-effective manner. By having the goals and objectives clearly defined, it
allows the policy to be tailored to the specific needs of the organization. The
maintenance policy should also be regularly reviewed and updated to ensure
that it is up to date with the latest technologies and practices. Furthermore, the
policy should be well communicated to all employees to ensure that everyone is
aware of their roles and responsibilities in the maintenance process. This helps
to ensure resources are used efficiently, and the maintenance team can
prioritize their tasks. It also allows for better forecasting of costs, enabling the
team to plan and prevent costly emergency repairs. Over the years we have had
types of maintenance evolve into classes of maintenance and then they are now
being called maintenance approaches. This article will only give brief definitions
of each. So much has been written about them that it would not add value for me
to dwell on discussing their merits and demerits. Here we would list all the
types, classes of maintenance and then understand how a strategy can be
developed using what we have listed here.
1. CORRECTIVE MAINTENANCE.
Corrective maintenance is a maintenance task performed to identify, isolate,
and rectify a fault so that the failed equipment, machine, or system can be
restored to an operational condition within the tolerances or limits
established for in-service operations. It is typically used when a piece of
equipment or system has failed or is not working properly. The goal of
corrective maintenance is to identify the root cause of the problem and make

3. the necessary repairs so that the equipment or system can be returned to its
intended operational state.
2. PREVENTIVE MAINTENANCE.
Preventive maintenance is maintenance that is regularly and routinely
performed on physical assets to reduce the chances of equipment failure and
unplanned machine downtime that can be very costly for maintenance teams
and facility managers. It is based on the idea of catching and fixing problems
before they become major issues. This can include oil changes, lubrication,
cleaning, and inspections. Performing these tasks regularly helps to keep
machines running smoothly and efficiently and to avoid costly repairs and
downtime. Sometimes its wrongly called Planned Maintenance. I believe
every maintenance activity should be planned and scheduled
3. RISK-BASED MAINTENANCE.
Risk-based maintenance (RBM) prioritizes maintenance resources toward
assets that carry the most risk if they were to fail. It is a methodology for
determining the most economical use of maintenance resources. This is done
so that the maintenance effort across a facility is optimized to minimize any
risk of a failure. RBM takes into account a variety of factors such as the age
of the asset, how critical it is to the overall operation, and the likelihood of a
failure. This allows for a comprehensive approach that focuses on the assets
that pose the greatest risk and have the greatest potential for failure. By
analysing these factors together, RBM can identify which assets should be
maintained more frequently and which can be maintained less often. This
allows for a proactive approach that can help reduce the risk of failure,
thereby optimizing the use of resources and minimizing the cost of
maintenance.
4. CONDITION-BASED MAINTENANCE.
In condition-based maintenance (CBM), maintenance is determined by
monitoring the actual condition of an asset. Based on CBM, maintenance
should only be performed if certain indicators indicate a decline in
performance or an impending failure. A lot of activities are carried out to
ascertain the equipment condition. Activities such as oil, vibration and
related analyses are common practices for successful condition-based
maintenance. This allows for preventive actions to be taken before a system
or asset fails, reducing downtime and costs associated with repairs. CBM
also enables greater flexibility in scheduling maintenance, as it can be
scheduled based on actual performance and not just time-based estimates of
when the asset might fail.

4. 5. RUN-TO-FAILURE MAINTENANCE,
Run-to-failure maintenance (RTF) consists of using assets until they
malfunction or require repair or replacement. This type of maintenance is
often used when the cost of repair or replacement is low or when the asset's
value depreciates over time. RTF is also used when there is a lack of
resources or personnel to perform regular maintenance on the asset.
However, operational managers sometimes deliberately choose RTF
maintenance as a form of reactive maintenance. This is because it can be a
cost-effective solution as it eliminates the need to purchase spare parts and
hire personnel to perform regular maintenance, as well as the need to
allocate resources to maintain the asset. Additionally, it can be less
disruptive to the operation since there is no need to perform regular
maintenance, which can lead to downtime. Some equipment which are on
continuous running basis use this method as well a lot of firefighting
equipment.
6. PREDICTIVE MAINTENANCE
A predictive maintenance technique is designed to assist in determining the
condition of in-service equipment and to estimate when maintenance should be
performed. Using these techniques allows for the proactive identification of
problems before they become major issues, thereby reducing downtime, and saving
money. In predictive maintenance, equipment performance is monitored, and data is
analysed to determine when maintenance should be performed. Because tasks are
only performed when warranted, this approach promises cost savings over routine
or time-based preventive maintenance. Equipment performance can be monitored in
real-time, allowing for quick detection of potential issues and early intervention.
Predictive maintenance also increases safety by ensuring that all equipment is
running at optimal performance and reducing the risks associated with unexpected
failures.
7. RELIABILITY-CENTRED MAINTENANCE.
Reliability-Centred Maintenance (RCM) is a corporate-level maintenance strategy
designed to optimize maintenance programs by establishing safe minimum levels of
equipment upkeep. RCM strives to identify the failure modes of equipment and then
sets up regular maintenance activities based on these failure modes to prevent
unexpected downtime or accidents. This helps to reduce the total cost of ownership
while also increasing the life of the equipment. In RCM, the emphasis is placed on
matching individual assets with maintenance techniques that are most likely to be
cost-effective. By understanding the failure modes of each asset, RCM can identify
the most effective maintenance techniques and schedules for each asset. This helps
to ensure the equipment is maintained in the most cost-effective manner and helps
to extend the life of the equipment.

5. 8. TOTAL PRODUCTIVE MAINTENANCE
Total productive maintenance (TPM) is the process of maximizing equipment
effectiveness through the active involvement of all supporting departments. TPM is a
proactive approach that works to reduce the amount of equipment downtime due to
maintenance and repair. It also aims to reduce the amount of resources used in the
maintenance process, resulting in increased efficiency and cost savings. This is
achieved by focusing on preventative maintenance, eliminating the root causes of
equipment failure, and improving the communication between departments to
ensure that maintenance tasks are completed on time and in the most efficient
manner possible. TPM encourages a culture of collaboration and teamwork between
departments, which leads to more efficient use of resources and improved
performance. The goal of TPM is to improve overall productivity by optimizing
equipment availability.
Reactive and Proactive maintenance are not mentioned here because the various
techniques, methods and approaches described above actually tells which is reactive
and which is proactive. I have done some classification in a previous presentation on
maintenance management.
It would be very important to discern that choosing one of the maintenance techniques,
methods, and approaches does not constitute effective strategy deployment. Effective
strategy deployment requires a holistic approach which includes setting goals and
objectives, developing a strategy to achieve them, and then implementing the strategy.
Maintenance techniques, methods, and approaches are only part of the puzzle and
need to be part of a larger strategy for it to be successful. Effective strategy
deployment requires that all facets of an organization be considered, including the
people, processes, and technology. Simply choosing a maintenance technique or
method is not enough to ensure that an organization's objectives are achieved. Other
issues to consider when developing the strategy would include, the right skills needed,
the method of service delivery (outsourcing or in-house) and other resources needed to
be deployed. This is because the chosen maintenance technique needs to be
implemented in the right way and with the right tools; it must be tailored to the specific
needs of the organization and the resources available to it. Additionally, strategies must
be monitored to ensure that they are being implemented properly and that objectives
are being met. Total Productive Maintenance comes close to a complete strategy when
considering all the seven pillars involved.
Maintenance strategy does not stop at choosing the right method, approach, or
method. It includes addressing issues such as the necessary resources required as
well as how to deploy them. It also involves deciding on the right time to perform
maintenance and establishing maintenance criteria. Lastly, it is important to create a
feedback loop to measure the effectiveness of the maintenance strategy and make
necessary adjustments. A successful maintenance strategy should also include a plan
for training personnel on the best practices for maintenance and ensuring that they are
kept up to date with the latest technologies and techniques. Finally, it is important to

6. create a plan for monitoring, tracking, and reporting on the performance of the
maintenance strategy.
MAINTENANCE PLAN
A plan is easily to evolve from the maintenance strategy and thence policy. A plan is
easily to evolve from the maintenance strategy and thence policy. The maintenance
strategy outlines the methods and procedures used to keep a system up and running,
while the policy is a set of rules governing the use of the system. The plan then serves
as the bridge between the policy and the maintenance strategy, defining the steps to
take to ensure that the policy is followed, and the system remains operational. The plan
should be regularly reviewed and updated preferably yearly to accommodate changes
in technology, personnel, and the organization. It should also be integrated into the
organization's overall operations plan so that the maintenance strategy is properly
aligned with the organization's goals. Finally, the plan should be communicated to all
stakeholders, so they are aware of the steps taken to keep the system running. Through
this, tasks can be undertaken that are most suited to reaching those goals, helping to
ensure the desired outcomes are achieved.
The plan outlines all the assets to be maintained and managed. It provides clear
guidelines on how to effectively keep track of these assets to ensure their integrity and
performance. The plan outlines the best practices for asset maintenance, such as
regularly scheduled inspections and preventive maintenance, as well as providing clear
procedures for identifying any potential issues. It also outlines the resources required
for asset management, such as personnel and materials, and provides guidance on how
to best use these resources. The necessary activities required are listed. The
frequency if applicable is also mentioned for each activity. By taking all these elements
into account, the plan ensures that asset maintenance is carried out in an efficient and
effective manner, resulting in reliable operation and minimal downtime.
MAINTENANCE SCHEDULE
The maintenance schedule is a list of timelines and action parties responsible for every
activity to be carried out to accomplish the goals set forth by maintenance leadership.
This includes regular inspections, repairs, and replacements of parts to ensure that
equipment is operating safely and efficiently. It also includes detailed instructions on
how to perform each task, as well as the appropriate materials, tools, and personnel
needed to complete it. The maintenance schedule allows maintenance leaders to
monitor and track the performance of maintenance activities and identify any areas of
improvement. It also helps to ensure that maintenance activities are being carried out in
a timely and cost-effective manner. It defines when any activity will be carried out and
who will carry out the activity. The various tasks to be carried out are also listed. Having
a maintenance schedule in place helps to ensure that all maintenance activities are
being carried out according to plan and that any deficiencies or improvements can be
identified quickly and addressed. This helps to prevent costly downtime and ensures
that all maintenance activities are carried out efficiently and effectively. Furthermore,

7. the maintenance schedule helps to ensure that all maintenance activities follow any
relevant regulations or industry standards. While a maintenance schedule is important
and beneficial, there are some drawbacks. For example, a maintenance schedule can
be inflexible, which can lead to issues if unexpected problems or maintenance needs
arise. Additionally, a maintenance schedule can be time-consuming to create and
maintain, which can take away from other important tasks. This is usually the case
when a maintenance strategy is not properly developed and deployed. A maintenance
schedule should be the outcome of a maintenance plan. an example is when developing
a preventive maintenance schedule because a method of maintenance identified for the
maintenance strategy includes preventive maintenance. The plan and schedule should
be clear reflections of the maintenance strategy. The maintenance plan should identify
the tasks and procedures that need to be done to ensure a comprehensive preventive
maintenance schedule is created and implemented. This will ensure the maintenance
strategy is properly implemented and executed.
MAINTENANCE RESOURCES.
Maintenance resources include material, labour, contract services, specialist
equipment, tools and information, and facility costs. The resources required for
effective maintenance management should be identified. This is necessary for the
successful implementation of the maintenance plan and schedule. With the right
maintenance resources, managers can plan, schedule and carry out maintenance
activities efficiently. Having the right tools and equipment available is key to minimizing
downtime and ensuring that repair and maintenance tasks are completed on time.
Additionally, having the right information on hand can help managers make informed
decisions and ensure that they are making the best use of their resources.
Having all the resources is good but effective management of these resources is verry
important to be explained in the strategy. Cost benefits must be identified for every
expense as well as utilisation of resources. Without effective management, resources
may be overused or underutilised, leading to inefficiency in operations and higher
costs. Additionally, a lack of cost benefit analysis can lead to decisions that are not in
line with the organisation's overall strategy, which can be costly in the long run.
Maintenance can sometimes be seen to be a thankless job. It's important to ensure that
maintenance activities are properly taken into account in cost benefit analysis to
ensure that resources are used responsibly and not wasted. This will help to ensure
that the organisation is able to maximise its efficiency and reduce costs. That mindset is
due to not realising the value it adds to the organisation’s well-being. Even at times of
zero equipment utilisation, maintenance is still needed. Maintenance helps to extend
the life of equipment and reduce the need for costly replacements. It also prevents
unexpected breakdowns and reduces the risk of safety issues. Proper maintenance can
also prevent costly repairs and downtime of the machinery, which can lead to the
organisation losing money. At times of zero utilisation, maintenance can help to prevent
deterioration of the machinery and keep it in good condition for when it is needed.
There must be a clear projection of both peak and low times with sensitivity to the
bottom line.

8. MAINTENANCE AS A BUSINESS.
As explained in previous write-ups and stressed by various distinguished professionals,
The first step to effective maintenance management is to see maintenance as a
business investment not as a necessary expense activity. Maintenance done properly
can eliminate the need for more expensive repairs and can help extend the life of
expensive assets. It can also increase safety and reduce downtime. Investing in
preventative maintenance and seeing it as a business investment can help reduce
overall costs and can help to ensure that the business is running efficiently. This can
lead to better customer satisfaction, higher quality products, and a more profitable
business. The equipment depreciates yearly, and this is provided for in company
accounts to make early arrangements in the event of a replacement. It would be a
failure for a piece of equipment to be replaced before its projected life span. It is as well
profitable when a piece of equipment very well exceeds its life span. By taking the time
to regularly inspect and maintain the equipment, businesses can reduce the risk of it
breaking down unexpectedly, which can result in costly repairs or complete
replacement. Regular maintenance can also increase the lifespan of the equipment,
potentially resulting in significant cost savings in the long run.
Every maintenance activity must be seen as a business activity expected to yield
financial dividends. This means maintenance should be seen as an investment in
reliability, rather than a cost. Achieving this requires an understanding of the business
value of maintenance activities, and the willingness to invest in them. There must be a
measurable index to determine the return on investment. By viewing maintenance
activities as business activities and implementing a measurable index to determine the
return on investment, organizations can make more informed decisions about which
maintenance activities are worth investing in and which can be left out. This will help
them maximize their return on investment and minimize their operational costs. This is
because maintenance activities are costly and require resources, time, and money.
Therefore, it is important to measure the tangible benefits that are generated from such
activities to determine if the investment is worth it. Maintenance success should not be
measured by cost savings alone but by evidence of improved productivity.