What Is Maintenance Management?
Maintenance management is a systematic approach to preserving and maintaining the physical assets and resources of a business. It involves organizing and executing tasks that ensure equipment, facilities, and infrastructure are in optimal condition.
By tracking equipment, workers, contractors, and associated costs, maintenance management systems help companies save money on repairs and inspections while ensuring safety, efficiency, and productivity for both employees and machinery.
Maintenance management software also helps reduce equipment failure and production downtime. It supports tracking of preventive maintenance schedules, which is essential for long-term operational success.
While practices may vary by industry, the main goal of any maintenance management system is to minimize resource waste. By ensuring smooth operations at every level, these systems aim to keep physical assets reliable and available whenever needed.
Today, this is achieved through a combination of manual processes, advanced tools, and computerized management software working together to maximize efficiency and effectiveness.
Why Is Maintenance Management Important?
For individuals outside the maintenance field, equipment failure might just be an inconvenience—like waiting longer for the subway or dealing with a power outage for a night.
However, for large companies, unplanned equipment failure can be catastrophic and costly. According to Aberdeen Strategy and Research, unplanned equipment downtime can cost a company an average of $260,000 per hour in lost revenue.
This is exactly what maintenance management systems aim to prevent. Industries such as transportation, IT, engineering, oil and gas, energy, and healthcare rely heavily on these systems to avoid significant financial losses.
Here are five key reasons why maintenance management is crucial:
1. Minimizes Equipment Downtime
Proper maintenance management helps prevent unexpected equipment failures, saving companies thousands or even millions in lost revenue. It ensures that downtime is planned and predictable, allowing for efficient scheduling of inspections and repairs.
2. Extends Equipment Lifespan
Maintaining equipment properly extends its lifespan, reducing the need for frequent replacements. This not only saves money but also minimizes waste. Well-maintained equipment can outlast multiple iterations of poorly maintained ones.
3. Increases Productivity
When all equipment functions correctly, employees can focus on more critical tasks rather than spending time on maintenance requests. This leads to higher productivity and less stress for the workforce.
4. Ensures Regulatory Compliance
Many industries have strict regulations that must be followed to avoid fines or accidents. Maintenance management software helps track and report compliance, ensuring businesses meet all necessary standards.
5. Saves Lives
In some industries, faulty equipment can lead to serious injuries or even fatalities. Proper maintenance management and safety protocols are essential to preventing such incidents and protecting both workers and the public.
Types of Maintenance Management
Now that we understand the importance of maintenance management, let's explore the different types of systems available.
There are five common types of maintenance management, ranging from simple to complex:
1. Run-To-Failure Maintenance
This is the most basic form of maintenance, where equipment is used until it breaks down. While it was once common, it’s now considered inefficient and expensive compared to modern alternatives.
2. Time-Based Maintenance
This involves performing maintenance at regular intervals, such as daily, weekly, or monthly. While effective, it may not always be the most efficient method.
3. Condition-Based Maintenance
This type uses sensors and monitoring systems to detect when an asset is experiencing issues. It allows for timely interventions before a breakdown occurs.
4. Predictive Maintenance
Predictive maintenance uses data analysis and machine learning to forecast potential equipment failures. It provides early warnings, enabling proactive repairs.
5. Prescriptive Maintenance
Prescriptive maintenance goes a step further by recommending specific actions to resolve issues. It offers tailored solutions based on real-time data, improving efficiency and reducing downtime.
Some maintenance tasks may need to be deferred due to limited resources, but prioritizing urgent needs helps maintain overall operational efficiency.
Maintenance Inspections
Inspections are a critical part of any maintenance management system. Whether conducted by humans or autonomous devices like drones, they play a key role in ensuring safety and efficiency.
There are several types of maintenance inspections, including:
1. Safety Inspections
Safety inspections ensure that all processes are safe for workers. They include checking first-aid kits, fall protection systems, and other safety measures.
2. Failure Finding Inspections
These inspections test backup systems to ensure they function correctly in case of a failure. They simulate failure scenarios to verify preparedness.
3. Building Interior Inspections
Interior inspections check for damage, wear, and tear inside buildings. They also ensure that plumbing, air filters, and other systems are functioning properly.
4. Building Exterior Inspections
Exterior inspections assess the condition of roofs, walls, windows, and other external structures. They identify issues such as leaks, cracks, or overgrowth that could cause problems.
Drones and Maintenance Inspections
Using drones for inspections improves safety and accuracy. Drones equipped with cameras and sensors can access hard-to-reach areas and provide detailed data without risking human safety.
For example, the Elios 3 drone features LiDAR technology that creates real-time 3D maps, making it ideal for confined space inspections.
While drones can be expensive upfront, their long-term benefits include reduced liability, lower inspection costs, and improved data quality. As drone technology becomes more affordable, its use in maintenance will continue to grow.
[Case study: Elios 3's 3D Mapping Helps City of Lausanne in Water Department Inspections]
Examples of Maintenance Management
Let’s look at how maintenance management software is being used across various industries:
1. Maintenance Management in Restaurants
Restaurants rely on proper maintenance of kitchen equipment to ensure food safety and customer satisfaction. A McDonald’s franchise owner saw significant improvements after implementing a CMMS, reducing repair times and equipment downtime by nearly 50%.
2. Maintenance Management in Construction
In construction, equipment failure can lead to costly delays. Effective maintenance management ensures safety, efficiency, and compliance with environmental and regulatory standards.
3. Maintenance Management in Hospitality
Hotels and resorts manage numerous maintenance requests daily. Implementing a CMMS improved response times, reduced errors, and enhanced guest and staff experiences.
Other industries using maintenance management systems include plastics manufacturing, automotive, healthcare, and more.
Maintenance Management Software
There are many maintenance management software options available, each tailored to different industries and needs. Here are some popular choices:
1. UpKeep
UpKeep offers a suite of tools for managing maintenance tasks. It focuses on automation and document management, making it ideal for businesses looking for an advanced CMMS.
- Industries of Expertise: Gyms, Food and Beverage, Government, Restaurants
- Current Clients: Marriott, Siemens, McDonalds
Learn more about UpKeep.
2. Aptean
Aptean provides customizable EAM and OEE software for various industries. Their solutions integrate with other enterprise systems for streamlined workflows.
- Industries of Expertise: Ports, Healthcare, Food and Beverage, Energy
- Current Clients: GE, Volvo, Ferring Pharmaceuticals
Learn more about Aptean.
3. ValueKeep
ValueKeep offers a comprehensive CMMS solution that reduces paperwork, lowers costs, and increases productivity. It includes inventory management, custom integrations, and support services.
- Industries of Expertise: Agriculture, Healthcare, Construction
- Current Clients: Ulster Rugby, The Mars Group
Learn more about ValueKeep.
4. Limble
Limble is designed to be user-friendly, helping teams save time on work requests and communication. It includes reports, spare parts management, and multilingual support.
- Industries of Expertise: Food and Beverage, Hospitality, Clothing
- Current Clients: Nike, Unilever, Pepsi
Learn more about Limble.
5. FMX
FMX offers asset management and CMMS solutions that improve efficiency and reduce costs. It includes facility rental, maintenance scheduling, and work order management.
- Industries of Expertise: Schools, Zoos, Nonprofits
- Current Clients: Wendy’s, Minnesota Vikings
Learn more about FMX.
Maintenance Manager Jobs
If you're considering a career in maintenance management, there are opportunities across various industries, including healthcare, manufacturing, and construction.
Roles can vary significantly depending on the industry. For example, an industrial maintenance manager may have different responsibilities than a facilities manager.
Despite these differences, there are common duties among all maintenance managers:
1. Managing Expenses and Preparing Budgets
Maintenance managers need to understand budgeting and expense tracking. Even with automated tools, knowing where funds are allocated is essential for efficient resource management.
2. Working with Contractors and Staff
Managing personnel, assigning tasks, and coordinating with contractors are key responsibilities. These interactions are crucial for maintaining smooth operations.
3. Overseeing Regulation Compliance
Maintenance managers must ensure that all operations comply with industry regulations. This includes adhering to safety standards and avoiding legal issues.
4. Reporting Progress
Effective communication and reporting are vital. Maintenance managers must interpret and share data to make informed decisions and improve performance.
Maintenance Manager Salary
The average annual salary for a maintenance manager is around $80,000 USD. Salaries can vary based on location and industry. Entry-level positions typically start at $55,000, while experienced professionals can earn over $100,000 annually.
Certain states in the U.S., such as New York and Minnesota, offer higher salaries for maintenance managers compared to others. Conversely, states like Idaho and Utah tend to pay lower wages in this field.
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