Prerequisites for conducting a successful predictive maintenance program

Predictive maintenance involves sensor installation on equipments to identify issues instantly. All the accumulated asset data goes into a software to alert in-house technicians. Many companies saved a lot of money post installing these devices. However, running a successful predictive maintenance program requires certain advance planning. 

In this article, we all cover all prerequisites to conducting a successful predictive maintenance program for efficient growth. But before that, let’s understand the proactive maintenance meaning.

What is proactive maintenance?

Proactive maintenance is a scheduled asset inspection that aims at identifying minor errors and default before major complexity. It eliminates the chances of sudden asset failure which drastically affects a company’s productivity. There are many other maintenance approaches including preventive, predictive, condition-based, emergency, and corrective maintenance. 

Another approach of asset maintenance is to use the proactive maintenance inspection approach. It involves finding errors and potential faults before they occur rather than after a breakdown which costs more than proactive maintenance and often leads to greater delays. 

#1 Implementing CMMS software

Manual tracking of all repairs, maintenance, and schedules needs to be more efficient and updated. The Computerised Maintenance Management System (CMMS) remains efficient in centrally monitoring tasks for increased efficiency. In other words, it’s nearly impossible to effectively and proactively manage more assets without some form of software support.

#2 Training and change management

Creating a preventive maintenance program is a challenging task for any individual. All stakeholders must be informed and involved. Traditional service practices will change, so training and change management are other prerequisites for a PDM program.

#3 Prepare enough resources

Make sure you have enough tools and personnel to perform scheduled maintenance regularly if you’re planning to do predictive maintenance. Having enough technicians ensure all tasks are effectively completed. Therefore, you end up avoiding unnecessary delays. 

#4 Provide necessary training

A complete transition from reactive maintenance to proactive maintenance requires some training. Everyone will need to know the new workflow, from machine operators and maintenance technicians to maintenance managers.

#5 Top management support from the beginning 

A successful predictive maintenance program requires support and funding from senior management. After all, the PdM process requires sufficient resources. This need is reflected in the resources allocated to hardware and software and in the deployment of maintenance personnel. Therefore, the program will likely fail in case of a lack of support from top levels. 

#6 Suitable condition monitoring methods & equipment.

Select the appropriate condition monitoring procedure once you select your predictive maintenance resources. This can relate to parameters viz. sound, vibration, speed, temperature, etc.

#7 Collecting and monitoring data 

Monitoring and collecting activation data helps establish the required baseline guiding further actions. The acquired data helps the algorithms identify the current asset health and any future mishap that might lead to complete failure. 

#8 Pilot testing

The choice of a pilot program depends on whether you are looking for short-term results or long-term benefits.

#9 Establishing a procedure

Consider hiring a full time technician to keep an eye on statistics and generate dashboard reports to report any breakdown. They have the authority to give instruction to shut down the system or to run it. 


Focus on these prerequisites to running a successful preventive maintenance program. Go ahead and start improving your overall plant maintenance. Implementing predictive maintenance will also help you gain a competitive advantage to increase business profitability. Any hindrance in output generation often leads to the overall disfunctioning of all business processes. Therefore, organizations shifting to predictive maintenance often enjoy considerable growth.

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