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The Predictive Approach, the Future Standard in Maintenance

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reading time : 2 min

Picture of Lucie Monnot
Lucie Monnot

Content Marketing Manager

To improve efficiency, an increasing number of French companies are choosing the predictive approach for maintaining their production equipment. This method is gaining ground over other maintenance management methods and could even become the standard within 10 years. The growth of dedicated software is expected to accelerate this trend.
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Optimiser gestion bons intervention maintenance

What is predictive maintenance?

Predictive maintenance is a proactive asset management method that uses data from sensors or other monitoring tools to forecast when a machine or piece of equipment is likely to fail. It makes it possible to intervene at the optimal time, just before a failure occurs, in order to avoid unplanned downtime and maximize asset availability.
 
This strategy is primarily based on the analysis of historical and real-time data. It enables fact-based decision-making, minimizing unnecessary interventions while ensuring equipment reliability.

Difference between predictive maintenance and preventive maintenance

Predictive maintenance and preventive maintenance are two approaches to equipment management, but they differ fundamentally in how they are applied.
  • Predictive maintenance: this approach relies on the collection of real-time data to predict when a breakdown may occur. It makes it possible to intervene only when necessary, thereby optimizing maintenance costs. It is more precise and personalized for each piece of equipment.
  • Preventive maintenance: this approach consists of carrying out interventions at regular intervals, based on time or usage cycles, to prevent breakdowns. It is planned in advance without taking the actual condition of the equipment into account, which can lead to unnecessary interventions or a risk of breakdowns between maintenance cycles.

A well-established approach

According to a survey by Reichelt elektronik, one of Europe’s leading online electronics companies, 43% of companies have already integrated predictive maintenance technologies into their industrial processes and facilities. However, 41% had to completely overhaul their equipment base in order to add sensors and AI. Finally, 16% had to update their maintenance solution to adapt to the modernization of their equipment base.

In addition to minimizing production losses and operational interruptions, managers are seeking time savings for their teams and greater visibility into maintenance activities. Finally, organizations want to move away from systematically replacing components at predefined intervals, as required by preventive maintenance. With a predictive approach, they avoid the expenses generated by unnecessary interventions, including labor and spare parts.

Although they recognize the importance of switching to predictive maintenance, companies regret the difficulty of finding the right tool among the wide range of solutions available. Others are held back by budget constraints, as the crisis has affected their revenue and, by extension, their investment capacity.
 
Despite these obstacles, organizations that have not yet integrated these technologies plan to take the step in the coming months or by 2022 at the latest. Since the beginning of the crisis, their digital transformation has become more important than ever if they are to remain competitive. If they all fulfill their commitments over the next few years, predictive maintenance should become the standard within a decade.

The benefits of preventive maintenance

Predictive maintenance enables companies to use data to anticipate anomalies in their machines. Their objective is to avoid, or at least limit, production shutdowns, which are inevitable if they act only after a breakdown occurs.
 
Their production equipment becomes more efficient, while they reduce repair costs and penalties resulting from temporary downtime across the production chain. These are significant advantages in a highly competitive environment.
 
To continuously monitor each piece of equipment and immediately identify potential malfunctions, companies equip themselves with dedicated tools. Sensors installed on machines measure various parameters and transmit them in real time to software that analyzes the data and triggers an alert in the event of a problem. Temperature, rotational speed, and other indicators should prompt teams to initiate a maintenance operation proactively.
Gestion de Flotte Définition, Avantages et Logiciel

How preventive maintenance works

Scheduling regular operations

Preventive maintenance is based on carrying out operations at predefined intervals, based either on time, known as calendar-based maintenance, or on equipment usage, such as operating hours or production cycles. These intervals are generally determined according to the manufacturer’s recommendations or the equipment’s performance history.

Systematic inspection

During each preventive operation, technicians inspect the machines to check their overall condition. They examine wear parts, such as belts, bearings, filters, and seals, which could cause a breakdown if they deteriorate over time. By identifying signs of deterioration in advance, they can carry out repairs or replacements before the problem becomes critical.
 
For example, if a bearing shows signs of fatigue or abnormal wear, it can be replaced before it breaks and causes a costly failure.

Equipment lubrication and cleaning

Preventive maintenance often includes basic operations such as lubricating and cleaning machines. These actions help maintain equipment performance at an optimal level. Proper lubrication reduces friction and wear on moving components, while regular cleaning prevents dirt and debris from accumulating and causing malfunctions.

Testing and calibration

Certain types of preventive maintenance require tests or calibrations to ensure that equipment operates within the required parameters. For example, in measuring or control equipment, regular calibration ensures that readings are accurate and comply with safety or quality standards.

Performance monitoring

Performance monitoring is a key aspect of preventive maintenance. It involves maintaining service histories detailing all operations carried out, the parts replaced, and technicians’ observations during inspections. This makes it possible to better plan future operations and adjust maintenance frequencies according to the actual condition of the equipment.
For example, if a machine shows signs of wear more quickly than expected, maintenance cycles can be adjusted to prevent premature deterioration.
Gagner en performance avec la maintenance à distance

How do you implement preventive maintenance?

Initial equipment assessment

The first step is to identify all equipment that is critical to the production process. This means determining which assets are essential to the company’s operations and which, in the event of a breakdown, would result in costly production stoppages. It is also necessary to analyze the condition of each machine and its breakdown history in order to determine which equipment requires particular monitoring.

Define maintenance intervals

Once the equipment has been identified, it is important to determine the frequency of interventions. This is based on several criteria:
  • Manufacturer recommendations: equipment manuals often provide recommended maintenance intervals.
  • Operating conditions: a machine used intensively or in difficult conditions, such as humidity or dust, may require more frequent maintenance.
  • Historical data: by analyzing past breakdowns, companies can adjust the frequency for each piece of equipment, avoiding both under-maintenance, which leads to breakdowns, and over-maintenance, which increases unnecessary costs.

Maintenance planning and scheduling

A preventive maintenance schedule should be established to plan operations regularly and systematically. This includes:
  • creating an operation schedule for each piece of equipment,
  • ensuring that maintenance does not disrupt production by scheduling it during production shutdowns or at times when the impact is minimal.
Good CMMS software, or Computerized Maintenance Management System software, can help automate this process by sending reminders for operations and documenting completed tasks.

Standardize maintenance procedures

It is important to define clear and standardized procedures for each operation. This ensures that all maintenance tasks are carried out consistently and efficiently. Each piece of equipment should have a procedure sheet detailing:
  • the tasks to be completed, such as checking filters, lubrication, or replacing parts,
  • the tools required,
  • inspection criteria and tolerances to be observed.
These sheets are essential for ensuring that technicians follow the same steps during every operation, thereby minimizing errors and omissions.

Train staff

The success of preventive maintenance depends on well-trained teams. Technicians must understand:
  • standard maintenance procedures,
  • how to identify early warning signs of failure,
  • how to use CMMS tools and diagnostic equipment.
It is also important to involve production operators in this process. They should be trained to identify and report operating anomalies, as they are often the first to notice a problem with a machine.

Use CMMS software

CMMS software is essential for organizing and monitoring a preventive maintenance program. It makes it possible to:
  • plan and document every maintenance operation,
  • track the history of breakdowns and repairs,
  • manage spare parts inventories,
  • analyze data to optimize the frequency of operations.
CMMS software also provides dashboards for monitoring equipment condition and maintenance costs in real time, as well as identifying machines that require particular attention.
Finding the perfect software for your company is not always easy. We have therefore written a comprehensive article on the subject to help you.
Discover the top 3 CMMS applications

Monitoring and continuous improvement

Once the program is in place, it is important to monitor it closely to ensure its effectiveness. This includes:
  • tracking KPIs, or key performance indicators, such as the breakdown rate, mean time between failures (MTBF), and maintenance costs,
  • conducting regular audits to ensure that maintenance procedures are being followed correctly,
  • adjusting maintenance frequencies and tasks based on feedback and the data collected.
Ultimately, although obstacles remain, particularly in terms of investment and tool selection, the trend is clear: predictive maintenance could become the standard in the coming years. Companies that integrate this strategy will position themselves competitively, ready to face future challenges while maximizing productivity and equipment lifespan.

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