PdM → PM → RM
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A common misconception by some in top management is that predictive maintenance (PdM) replaces or is separate from preventive maintenance (PM). In actuality, PdM drives PM.

PM is a time-based approach whereby maintenance professionals perform scheduled actions. Often, these actions are performed in the absence of data, but with good intentions, as part of a well-established routine. Many of these actions are necessary for the assets to continue to operate effectively, efficiently and safely. However, the proper frequency and extent are not known because no two assets are exactly alike, and the result is an inefficient use of capital.

Most reliability processes have aspects of PdM, PM and reactive maintenance (RM). Implementing PdM allows organizations to move from a time-based or routine maintenance schedule to a maintenance schedule based on asset condition, specifically severity and likelihood of failure. Simply, implementing PdM allows companies to shift from a reactive to proactive maintenance approach.

Assess Your Own Maintenance Process
Consider the questions below. Give yourself one point for each “yes” answer and zero points for each “no” answer. Remember, honesty is the best policy!

# Our... Answer
1 Our maintenance team schedules preventive maintenance based on analysis of machine condition data
2 Purchasing works closely with maintenance to plan for spare parts inventory
3 Our maintenance team knows which machines are most likely to fail, when and in what way
4 Top management understands that our organization can expect a ten to twenty times return for capital invested in predictive technologies
5 Failure rate data is readily available
6 Maintenance team understands the health of our equipment better than our equipment suppliers
7 Our maintenance team operates the maintenance process using a formal management system, invoking well-established PA/CA processes
8 Maintenance planning meetings focus on reducing maintenance efforts, as well as addressing current required maintenance
9 Reliability performance is measured in terms of process effectiveness and efficiency, inclusive of return on assets
10 Maintenance expenditures, as a ratio of money spent to total revenue, has decreased by >25% over the past three years

Breaking the routine of reacting to problems instead of planning to prevent them is not easy. It often involves a significant cultural change supported by data-based results. However, most people agree that making this change is not an option for companies to survive, it is a necessity.

Implementing PdM Within Your Reliability Process

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