It’s well-established that utilizing a planned or preventative maintenance program can save you thousands of dollars every year in maintenance and repair costs, extend the lifespan of your equipment and reduce downtime. Regardless of the potential benefits, however, many operations do not utilize preventative maintenance at their facilities. For some of these businesses, there’s a degree of uncertainty surrounding the benefits of preventative maintenance and how to transition from their current maintenance strategy to a more proactive approach. To address those concerns and provide a simplified path forwards, we’ll review the key benefits and provide a basic guide on how to implement a planned maintenance program below:
Select Your Equipment
The first step in establishing a successful preventative maintenance program is to select what equipment will be included. To create your list, we recommend that you consider the following factors to maximize the impact and ROI:
Basically, you should select equipment that will require frequent maintenance and/or have higher replacement or repair costs as this will provide a better return on investment. Conversely, you should omit older models that are reaching the end of their economic life as these will need to be replaced soon anyways.
Gather All the Necessary Information
To ensure you’re preventative maintenance plan will provide a positive ROI and saves money for your business at the end of the day, you could calculate your potential savings for each asset. To do this, you’ll need to determine what maintenance tasks are performed on each unit, the frequency of those tasks and your current costs. To do this, you should check the manufacturer’s service recommendations, check your vehicles service history and maintenance reports, and consult with your service technicians, maintenance staff and operators. You’ll also want to consider the hidden costs of a reactive approach to your maintenance needs such as lost productivity due to downtime, unnecessary repairs and a short equipment replacement cycle.
Implement, Track and Adjust
Once you’ve established your list of equipment and collected your data, it’s time for the implementation phase. One of the key factors in successfully implementing your program and maximizing your ROI is maintenance scheduling. To minimize the impact of equipment maintenance on your operation, you should schedule downtime for maintenance during off-peak hours and/or off-set maintenance for multiple forklifts.
After that, it’s all about tracking and making adjustments. While you took the time to gather data and carefully design a PM program that meets your business and maintenance needs, there are always improvements that can be made. This will help you avoid overscheduling maintenance tasks while ensuring all of your equipment is properly serviced and repaired, thereby ensuring a positive return on investment.
To analyze and adjust your program, consider the number of breakdowns or failures per machine (if any) and compare that with its maintenance schedule. If a forklift did not experience a single breakdown, it’s possible that it could continue doing so with less maintenance. On the other hand, if a unit experiences regular breakdowns in spite of the regular inspections and preventative maintenance performed on it during this period, you likely need to increase the maintenance frequency once the cause of these breakdowns has been diagnosed and addressed.
If planned, implemented and tracked properly, planned maintenance programs are a great way to save on maintenance costs, improve productivity and improve the safety of your operation. In the end, a PM program can save you up to 70% on your maintenance costs if properly implemented and adjusted – and that’s before accounting for the hidden costs associated with increased downtime and lost productivity. Through our planned maintenance agreements, your business can save thousands of dollars per year in maintenance-related expenses, as well as avoid the indirect costs of equipment failures such as lost productivity and/or safety-related issues such as employee injuries, government fines and shutdowns. For more information on the benefits of participating in one of our planned maintenance programs or details about our forklift repair services, feel free to contact Lucas Liftruck today!