eMaint, A Fluke Reliability Brand - December 2025
Equipment maintenance is the process of ensuring that machinery, tools and other equipment continue to operate efficiently and safely. It involves regular inspection, testing, servicing and repair of equipment to prevent unexpected failures and extend operational life. The maintenance can be both routine and corrective. Basically, it’s any work that maintains vital assets, whether heavy machinery or small technical tools.
Effective equipment maintenance reduces downtime, improves safety and increases efficiency and productivity, making it a fundamental part of asset management. Equipment maintenance can be further optimized through the use of a computerized maintenance management system (CMMS). From tracking assets to scheduling maintenance, a good CMMS makes everyone’s job a little easier.
There are different methods of equipment maintenance, each with its specific purpose and approach. A robust equipment maintenance strategy will encompass a range of approaches and activities aimed at keeping machinery in optimal condition. Regular and well-planned maintenance ensures that equipment operates reliably, supporting productive, safe operations.
Preventive maintenance involves scheduled inspections and routine equipment servicing to prevent potential problems. The goal is to identify and address issues before they cause a breakdown. Activities can include oil changes, lubrication, alignment and replacing parts.
Predictive maintenance uses data analysis and monitoring technologies to predict when equipment might fail. By analyzing data from sensors and historical performance, maintenance teams can schedule repairs just in time to prevent failures, optimize maintenance schedules and reduce costs. Think of it as a tech-enhanced version of preventive maintenance.
Also known as corrective maintenance, this approach calls for repairs after a machine breaks down or a part fails. It involves fixing or replacing components only when they are not functioning correctly. Initially, avoiding routine service can reduce maintenance spending but the cost of replacing an entire machine often outweighs any short-term savings. Preventative equipment maintenance might slightly increase your monthly costs but a prolonged asset lifetime makes it a worthwhile investment.
Condition-based maintenance involves monitoring the actual condition of equipment to decide what maintenance needs to be performed. It often uses real-time data from performance metrics, inspections and tests to determine the required maintenance actions. Once equipment usage reaches a predetermined point, a maintenance task is created to maintain
peak performance and efficiency.
Implementing a multifaceted equipment maintenance program offers numerous benefits to companies. Here are some of the key advantages of regular equipment maintenance:
Increased equipment lifespan: Regular maintenance helps extend the life of machinery and equipment by addressing wear and tear. This practice ensures that components are always in good working condition.
Reduced downtime: Preventive and predictive maintenance strategies help identify and address potential issues before they result in equipment failures. When these strategies are implemented, organizations see a reduction in unexpected downtime, ensuring continuous operations and productivity.
Cut maintenance costs: While maintenance requires a budget, a proactive approach can reduce costs. Emergency repairs and equipment replacement can significantly eat up maintenance funds. Effective, proactive maintenance can lead to significant cost savings over time by reducing the need for major repairs and extending equipment lifespan.
Improved safety: Properly maintained equipment is safer to operate, reducing the risk of accidents and injuries. Regular inspections and servicing ensure that safety features function correctly, protecting workers and equipment.
Enhanced performance: Well-maintained equipment operates more efficiently, leading to better performance and productivity. Regular service ensures that machinery runs optimally, reducing energy consumption and improving output quality.
Regulatory compliance: Many industries have regulatory requirements for equipment maintenance to ensure safety and environmental standards are met. Adhering to these regulations helps organizations avoid fines and legal issues.
Better resource management: Maintenance planning and scheduling promote resource optimization, including using spare parts and labor. This leads to more efficient operations and better inventory and personnel management.
Equipment maintenance takes many forms. What a maintenance task entails depends on the type of asset being worked on and whether it’s a routine or corrective task. Some common examples of equipment maintenance are:
■ Oil changes
■ Filter replacements
■ Cleaning and sanitizing
■ Lubrication
■ Calibration and alignment
■ Software or firmware updates
■ Parts repairs or replacements.
However, the most common and often most important form of equipment maintenance is the inspection. You can only fix equipment if you know there is a problem. Routine inspections scheduled at either a strict cadence or at consistent usage triggers are the backbone of all optimized equipment maintenance strategies.
Proper maintenance can extend the life of equipment and increase workplace productivity but only when it’s done correctly. Equipment maintenance is easy if you have the know-how. Here are some best practices to get you started.
Inventory your equipment: Knowing exactly what you are dealing with will stop anything from falling through the cracks. Take stock of the equipment your company is using, its age and its manufacturer-recommended maintenance windows. This will help you create a maintenance plan and avoid scrambling to find machine-specific repair methods in the future.
Keep equipment clean: It sounds simple but consistently cleaning equipment improves its performance. Dirt and grime can easily clog filters or cause electrical system issues.
Always use equipment correctly: Avoid unnecessary issues by always using equipment as directed by the manufacturer. Machines already wear down on their own, no need to speed that process up through improper usage. Follow the instructions for increased longevity.
Don’t skip alignment and lubrication: Misalignment can be a silent problem that takes years off an asset's lifetime. Always ensure that your equipment is properly aligned and calibrated so it consistently runs at peak efficiency. For equipment with moving parts, reduce friction as much as possible through consistent lubrication.
Choose a maintenance strategy that fits: When building your equipment maintenance strategy, ensure that it makes sense for your company. Condition-based maintenance might sound great but if you lack the capabilities to easily monitor asset usage, it may not be the right fit. On the other hand, it could be cheaper to replace your equipment than constantly service it. In such cases, reactive maintenance may be the best choice.
Make timely repairs: Don’t let routine service go overlooked. Sticking to the recommended maintenance schedule is crucial to keep equipment in good condition. Having a solidly scheduled maintenance plan can greatly help in this regard.
Use a CMMS: Consider a CMMS as your maintenance command center. Track assets, schedule maintenance and gather insights into usage and equipment health.
Equipment maintenance software plays a critical role in managing and optimizing maintenance activities. Solutions like eMaint are computerized maintenance management systems. A CMMS provides tools and features that help maintenance teams plan, execute and track maintenance tasks effectively. Here are some key features and benefits of equipment maintenance software:
Automated scheduling: A CMMS can automate routine maintenance task scheduling based on predefined intervals or real-time data. This ensures that maintenance activities are carried out on time, reducing the risk of equipment failures.
Asset tracking: The software allows for detailed tracking of every asset, including maintenance history, performance data and upcoming service requirements. With this information, teams can maintain a comprehensive record of each piece of equipment.
Investing in equipment maintenance software like CMMS can greatly enhance maintenance program efficiency and effectiveness. By leveraging the advanced features of these tools, companies can optimize their maintenance activities, improve equipment reliability and achieve significant cost savings.
Meet eMaint, the revolutionary CMMS, EAM and IIoT software from Fluke Reliability that connects hardware and software in a cloud-based ecosystem, empowering you to boost uptime, strengthen reliability and drive production. For more information, visit www.emaint.com.