Choose the right maintenance strategy for your operation

A maintenance strategy is the overall framework and direction an organization uses to care for its physical equipment. The work is about making systematic decisions on when, how and why equipment and machines should be serviced to achieve high operational reliability at the right cost. Choosing a maintenance strategy is fundamentally about finding the right strategy for the right equipment and directly affects business profitability and equipment lifespan.

Different maintenance strategies

There are several maintenance strategies to choose from, and often a combination is used depending on how critical a specific machine or piece of equipment is to production. The work is based on the international standard SS-EN 13306 for how professional operations classify their activities.

Corrective maintenance

Corrective maintenance means repairs are performed only after a fault has occurred. It is suitable for low-criticality equipment where a stoppage does not incur significant costs or safety risks.

Preventive maintenance

Preventive maintenance involves carrying out actions at predetermined intervals to reduce the likelihood of failures. It can be based on calendar time, operating hours or cycles. The goal is to replace components before they fail.

Condition-based maintenance

Condition-based maintenance is a more advanced form of preventive action. Using sensors and measurements, such as vibration analysis or oil sampling, the condition of equipment is monitored. Actions are taken only when measurements indicate an emerging fault.

Predictive maintenance

Predictive maintenance relies on collecting large amounts of data to predict when a fault is likely to occur. Machine learning and intelligent algorithms analyze historical data combined with real-time information and aim to minimize unnecessary component replacements.

Combine methods

Combining several methods is industry standard. Choosing a maintenance strategy is about finding the right strategy for the right equipment, and applying the right strategy to the right machine contributes to a more cost-effective way of working. This methodology is called RCM (Reliability-Centered Maintenance) and is based on creating a balance between corrective, preventive and predictive actions according to the equipment’s specific needs. Such an approach gives staff the right conditions to spend their time where it delivers measurable results for the facility.

Choosing a strategy based on criticality analysis

Choosing the right maintenance strategy for your operations requires a thorough review of all parts of the facility. A criticality analysis helps you identify which equipment requires the most resources:

1. Identify critical units: Which equipment causes a complete production stoppage if it fails?

2. Assess risks: Analyze consequences for environment, health and finances

3. Choose method: Apply condition-based maintenance to critical components and corrective maintenance to non-critical components

Example

We can illustrate the method with a fictional example from a sawmill. The company identifies the main saw blade as the most critical unit, since an unplanned stop immediately blocks the entire line. The team applies a condition-based approach there with automatic vibration monitoring. The chip conveyors are assessed as moderately critical and put on a calendar-based preventive maintenance schedule. General warehouse lighting is handled with a corrective approach, where lamps are only replaced when they fail. This kind of allocation often leads to a measurable reduction in unplanned production stoppages.

Standardization and legal requirements

Strategic maintenance work is governed not only by internal goals but also by legislation. Arbetsmiljöverket requires that equipment be maintained so that it does not pose a safety risk to personnel. A documented maintenance strategy shows that you take responsibility and comply with the applicable rules for systematic work environment management (SAM).

"Work equipment shall be maintained so that it continuously meets the requirements and can be used safely throughout its service life." – Arbetsmiljöverket (AFS 2006:4)

From strategy to a concrete plan

When your operation has chosen the right maintenance strategy for each machine or piece of equipment, the next step is to build a detailed maintenance plan. The plan specifies which tasks your staff should perform, at what intervals they should be done and which spare parts are needed. A structured maintenance plan acts as a direct translation of the strategy into daily work orders — a bridge that gives personnel the right conditions to do their work.

Follow-up with a digital maintenance system

Data is an important resource for evaluating whether chosen maintenance strategies deliver the desired results. A digital maintenance system (CMMS) gathers history and costs in one place. Analysis of key metrics such as MTBF (Mean Time Between Failures) and MTTR (Mean Time To Repair) provides answers on whether the strategy needs adjustment.

A digital tool for maintenance planning makes it easy for technicians to report back in real time. The information becomes part of the company’s collective knowledge and facilitates future investment decisions.

How often should a maintenance strategy be evaluated?

The recommendation is to review it annually or in connection with major changes in the machine fleet. Continuous evaluation keeps the working methods relevant for operations.

Checklist: 5 steps to a better maintenance strategy

This checklist gives you a clear overview to get started

• Inventory all machines and technical equipment at the facility

• Conduct a criticality analysis to identify the most important machines
• Choose an appropriate maintenance strategy for each machine class
• Document routines and create an ongoing maintenance plan
• Follow up results using the system’s key metrics and adjust the method continuously