Types f

Maintenance:
the ultimate guide
Everything you need to know about the
top maintenance techniques and how to properly
implement them in your plan.
SUMMARY 03. Introduction

05. Corrective Maintenance

06. Unplanned Maintenance
07. Planned Maintenance

08. Preventive Maintenance

09. Time Based Maintenance
10. Condition Based Maintenance

11 Predictive Maintenance
. 12. Sensitive Maintenance
13. Monitoring Predictive Maintenance

16 Prescriptive Maintenance

.
17 Support Maintenance
.
18 The secret to good maintenance management
.
One often hears people talk about
"maintenance activities" as if they were
universal, but that is not quite true.

There are some main types of maintenance

and, in between, subtypes that can cause
mix-ups if not thoroughly understood.

You definitely know the terms "corrective",

"preventive", and "predictive", but knowing
what these three general concepts mean is
not enough. For the maintenance plan
to be assertive, preventing failures and
reducing costs in the department, the
manager must master all types and
subtypes of maintenance - and that is
exactly what TRACTIAN will teach you in
this exclusive material.
By digging more deeply into the theory, you become
even more qualified for the job of assigning the ideal
activity to each asset, defining precisely what to do,
where, and when.

Regardless of your experience in the sector, you will

leave this reading knowing everything about the eight
most important types of maintenance, as well as their
differences and ideal application scenarios - content
adapted by TRACTIAN based on the book “A Anatomia
do PPCM” (The Anatomy of PPCM), by José Wagner
Braidotti Jr.

And remember: the dream plan involves all types of

maintenance while prioritizing intelligent tools,
which make maintenance activities even more
effective and profitable.
Corrective Maintenance
Corrective maintenance is the oldest, least complex, and
most expensive maintenance. But this does not mean that
it is bad nor that it should be left out of the plan.

This practice is about fixing or replacing components

after failure or when the failure is about to happen.
It is often unscheduled, which increases its financial
impact (because it is costly and delays production).

Therefore, corrective maintenance, and especially

emergency corrective maintenance, should not be
excluded from the plan, but avoided with the help of the
other types of maintenance.

Not everything is predictable and avoidable, and the

manager must always be prepared for a "surprise"
replacement or repair of critical equipment.

As we have said before, there are subtypes within the

most well-known types of maintenance.

When it comes to corrective maintenance, we can

separate it into two categories, based on the
predictability of the failure that the intervention
seeks to correct. Learn more about each one of them in
the following pages.
Unplanned
Corrective Maintenance
This is the one we call "corrective", "emergency" or "reactive"
maintenance - and some may call it Non-Predictable Corrective
Maintenance.

Basically, it is an unplanned maintenance activity performed after

the occurrence of the asset's functional failure.

Because it is a surprise for the maintenance team, the ideal

scenario is that the functional failure that precedes a
corrective activity occurs in less critical equipment. Thus, the
financial impact is lower, since the latter are usually simpler and
cheaper to repair or replace, and do not affect the production flow.

To ensure that the most important machines to the operation do not

need emergency corrections, the manager should prioritize other
maintenance techniques in the plan, such as online - and constant -
monitoring of critical assets, which we will present later.

Types of maintenance 6
Planned
Corrective Maintenance

Also known as "urgent", it is the scheduled and

intended maintenance activity that takes place after
the occurrence of the functional failure in the
machine.

Unlike the previous one, it is mainly used to solve

problems that do not directly affect the
operation of the equipment.

Since it is programmed, it is much more economical,

safer and faster than emergency corrective
maintenance. Such planning is generally defined
based on predictive or detective monitoring of the
component, and can be applied to assets of high and
low criticality.

Types of maintenance 7
Preventive Maintenance
In order to ensure the efficiency and reliability of
industrial machinery, preventive maintenance works with
activities of detection, replacement, and repair of
components and assets before any failure can
occur.

According to the definition set by the Brazilian Association

of Technical Standards (ABNT), preventive activities seek
to reduce machine wear and the chance of equipment
failure, which usually come along with improper
operation.

Preventive maintenance activities are, in practice, the

so-called periodic overhauls, routine lubrication,
calibrations, and inspections.

But while preventive techniques are already very popular,

one thing that not all managers know is that they fall into
two types of maintenance: time-based preventive
maintenance and condition-based preventive
maintenance.

As you will discover in the next pages, it is important to

know the differences and uses of each group in order to
schedule more precise interventions and make your plan
more strategic.
Time-
Based Preventive Maintenance
This is the one we usually call "preventive". Its activities
are defined according to the usage time of the asset
at issue, which usually belongs to the most critical
groups (A and B).

The interventions, always periodic and pre-determined, do

not usually require skilled labor and can be performed by
the team's own operators after some training. These
actions can be visual inspection, lubrication, machine
cleaning, and anticipated component replacement,
depending on the age of the asset.

While great for saving resources, extending equipment life,

improving operation, and preventing accidents, TBM can be
more random than effective. We often establish shorter
intervals for preventive activities, which leads to
unnecessary shutdowns and replacements. The goal is to
combine this technique with a more assertive and
data-driven one.

Types of maintenance 9
Condition-
Based Preventive Maintenance
We call that the maintenance activity that takes
place after the periodic diagnosis (TBM) is
performed in the field. Unlike the latter, this one
is based on the actual condition of the physical
asset: how is it operating? Does it meet the
expected functionality?

The main tool used here is another type of

maintenance, the predictive one. With real-time
data collection and detailed diagnostics offered
by predictive systems, it is possible to define,
plan, and conduct more accurate preventive
actions based on external and internal aspects
of the machine.

Unlike TBM, Condition-Based Preventive

Maintenance requires advanced technical knowledge
and is usually outsourced. Yet in the last few years,
technologies have emerged to take the specialists'
place. Like Tractian's online monitoring, they are
easy to implement and control and require no
training.

Types of maintenance 10
Predictive Maintenance
Like the previous one, predictive maintenance is based
on the current conditions of the asset, and can be
classified as routine monitoring, ideally done in real
time.

This monitoring seeks to reduce equipment failure

and wear through the collection and analysis of
data and performance metrics. Based on these
results, it analyzes the operational condition of the
assets.

Some of the smartest and most advantageous tools for

maintenance today derive from predictive maintenance
practices, such as online monitoring softwares.

With these tools, the manager is aware of everything

that happens in the equipment, 24 hours a day, and
receives precise diagnoses and data that help in
creating a strategic plan, with corrective and
preventive activities programmed in a deliberate
and wise way, and not unnecessary and
randomly.
Predictive Maintenance
Sensitive Maintenance
Also known as "detective," Sensitive Maintenance
identifies the operating condition of physical assets
through sensory routes. It basically uses the four
senses of the workers (sight, hearing, smell, and
touch) to evaluate the assets. It is, therefore, a
diagnostic activity that looks for potential failures - a sort
of investigation.

At first glance, it may seem simple, but make no

mistake. It is a job that demands a lot of attention
from employees to the smallest details: their eyes,
ears, nose, and touch must capture as much information
as possible during the sensory routes and compare these
data with the ideal conditions for each asset.

This investigative character brings us to Detective

Maintenance, a variation of Sensitive Maintenance. It
consists of a set of processes whose purpose is to
verify the protection systems of the machines, going
further than the full monitoring of the devices.

Types of maintenance 12
Monitoring Predictive Maintenance
When you think of Predictive Maintenance, what
probably comes to mind is the definition of MPM. Its goal
is to identify the operating condition of physical
assets through constant measurements of
quantitative technical parameters - such as
temperature, vibration, and noise.

In addition, it is a diagnostic activity that, like sensing

and detecting, looks for potential failures. In other
words, functional failures that have not happened yet,
but have already started to show symptoms in the
equipment.

MPM's means of investigation, however, are not the four

senses of the technicians, but the 24/7 data collection.
With online monitoring software based on artificial
intelligence, IoT, and data science, all variations and
failure symptoms manifested by the equipment are
detected and analyzed, ensuring that the the
manager and the team know exactly what, when
and where to do to preserve the operation.

Types of maintenance 13
Monitoring Predictive Maintenance (MPM)
Continued

This is exactly what TRACTIAN does. After being connected to the most critical
assets, our IoT sensors listen very carefully to everything the machine says
(because it speaks all the time). This information is analyzed and provided to the
team in a platform that also optimizes the department's work, by sending diagnoses
and precise insights about the activities that must be performed. All this in only
one tool.

Solutions like this make the plan more strategic and efficient. Besides facilitating the
team's work and allowing operators to focus on more important activities, such
technologies help the manager to define which corrective and preventive
actions should be performed, when and where.

The maintenance sector thus becomes much more profitable and beneficial
to the company's competitiveness, since it not only significantly reduces the
occurrence of worrying failures and unexpected production stops, but also cuts
down on maintenance costs.

Types of maintenance 14
BENEFITS OF
ONLINE MONITORING

1 Fewer unexpected failures;

4 Increased efficiency in the processes;

2 More accurate data and information;

5 Improved equipment reliability;

3 Easy and clear identification of the problem;

6 No more random repairs and time
waste.

Types of maintenance 15
Prescriptive Maintenance

Due to the rise of increasingly advanced technologies, the concept of

Prescriptive Maintenance has emerged in the age of Industry 4.0. Its role is
to use artificial intelligence to develop solutions for identifiable
potential failures.

Unlike preventive maintenance, prescriptive maintenance is not tied to a

schedule that focuses on common failures. And compared to predictive
maintenance, it goes further, since it not only accurately predicts what will
happen, but also suggests interventions based on the possibilities estimated
by analyzing the data.

Does this remind you of something? In the previous topic, about monitored
predictive maintenance, we used the TRACTIAN solution as an example, and
it also relates to prescriptive maintenance.

The online monitoring system is based on predictive and prescriptive

maintenance practices, the latter being made possible by cross-referencing
historical operational data and using artificial intelligence on the collected
information, which allows the maintenance team to know what to do
when any anomaly is detected.
Support Maintenance

The last type of maintenance is made up of activities that

are not part of the routine of specialized departments and
that work to improve physical assets.

This group includes small reforms, repairs, and modifications

that are required in the facilities and are directly conducted
by the maintenance teams.
The secret to good
maintenance management
A lot is said about what are the best definitions and terms for each
type of maintenance, but there are few solutions that really
improve the maintenance sector nowadays.

Now that you already know the main types of maintenance, their
differences, forms of implementation and most effective tools, you
are one step ahead of the competition when it comes to putting all
types of maintenance into practice, distributing the activities and
percentages of performance in a strategic way.

And the best choice is always to prioritize

technology and its intelligent tools to
anticipate problems and have more control
over the machinery.

Types of maintenance 1
All types of maintenance have advantages and
disadvantages - that' s why it is important to
integrate them and make one complement the
lack of the other. After all, from corrective to
prescriptive, all practices have the same
goal: to improve and maintain asset
To ensure that the goal is achieved successfully, always
availability and reliability.
remember that technology is the best friend of the 4.0
manager, who does not just want to make machines work, but
rather keep them reliable and available. If you want to join
this group and change the maintenance achievements in
your industry, know you can count on TRACTIAN.