6 Types of Preventive Maintenance to Consider for Your Equipment

Although most maintenance managers understand how important the various types of preventive maintenance can be, creating and implementing an effective preventive maintenance program remains a common hurdle.

That’s because reactive maintenance is oftentimes considered the cheaper, less time-consuming approach, especially for teams with limited resources. But creating a preventive maintenance plan doesn’t have to be complex. And the pros of implementing proactive maintenance far outweigh the cons. Think smoother operations and fewer unexpected breakdowns for teams managing various pieces of equipment. 

Let’s explore how these proven types of preventive maintenance (PM) can strengthen your PM program.

What Is Preventive Maintenance? 

Preventive maintenance prioritizes equipment care, with regular inspections and service work to keep machines running properly. Rather than fixing problems after they break down, maintenance teams spot and fix issues early, helping prevent equipment failure.

Inspections, cleaning, lubrication, parts replacement and fine-tuning equipment settings are all examples of preventive maintenance. Maintenance technicians perform these tasks according to specific schedules. Performing oil changes quarterly, checking equipment weekly and following manufacturer recommendations are standard practices.

These preventive maintenance tasks reduce downtime, prolong equipment lifecycle and ensure reliable operations. And consistently following this practice protects investments in critical assets and supports operations.

Benefits of Preventive Maintenance

Managing equipment without a maintenance plan leads to rushed work, costly repairs and stressed-out teams. A preventive approach changes that narrative, offering improvements across four major areas, including: 

Minimizes Unplanned Downtime

Ongoing preventive maintenance reduces unexpected equipment failures. When maintenance teams follow a consistent preventive maintenance schedule, they catch and fix minor issues before they cause breakdowns. When teams properly maintain a machine, it runs more reliably, reducing emergency repairs and production delays.

Extends Equipment Life

Equipment lasts longer with scheduled maintenance activities. Consistent cleaning, lubrication and parts replacement help machines operate within ideal conditions, reducing wear and tear. Maintaining equipment properly can improve functionality, making it last years longer than expected.

Controls Maintenance Costs

Planned maintenance schedules improve cost savings. Organizations spend less on emergency repairs, rush-ordered parts and overtime labor. And when managers can predict maintenance budgets better, it also makes resource planning easier.

Reduces Safety Risks

Safety improves when equipment receives regular attention. Worn out parts or malfunctioning safety features can cause accidents. But inspections identify potential risks that can help prevent them.

While there are more benefits of preventive maintenance, these four key examples apply to all six types of preventive maintenance that we’ll explore.

6 Different Types of Preventive Maintenance 

Different kinds of equipment and operational needs require different types of maintenance strategies. With the right mix of these six approaches, teams can protect their equipment and use their resources more effectively. 

Understanding and implementing these types of preventive maintenance require careful planning and often benefit from cross-departmental collaboration between maintenance teams, operations managers and financial planners.

Time-Based Maintenance 

Performing regular equipment maintenance at set time intervals creates a reliable foundation for maintenance teams. Managers should establish fixed service dates — daily, weekly, monthly or annually — rather than waiting for problems to occur. 

The effectiveness of this approach stems from its alignment with manufacturer recommendations and industry standards. For example, electrical systems often require annual thermographic inspections, while air-handling units typically need quarterly filter changes and belt inspections. These standardized intervals help maintain warranty coverage and ensure consistent equipment performance.

Managers often choose this method first because it provides clear structure and measurable outcomes. It’s particularly effective when combined with detailed maintenance logs and documentation systems that track service history and help identify patterns in equipment performance over time.

Used For

• Production machinery with standard service requirements
• Facility systems that need consistent inspections
• Equipment with manufacturer-specified maintenance intervals
• Assets operating in stable, predictable conditions
• HVAC systems requiring regular filter changes and inspections
• Standard lighting systems needing periodic bulb replacement

Pros

• Creates predictable maintenance schedules
• Establishes clear budget and resource needs
• Supports regulatory compliance requirements
• Simplifies staff scheduling and resource allocation
• Helps standardize maintenance procedures and workflows across similar equipment

Meter-Based Maintenance 

A machine might need service after 10,000 cycles, 500 operating hours or 100,000 units produced, so actual use determines this type of PM strategy. Maintenance teams monitor runtime, mileage, production counts or other metrics to plan their work effectively.

Equipment usage often predicts maintenance needs more accurately than time alone. The maintenance requirements of, say, two identical forklifts might be very different if one is used more frequently than the other. A forklift that’s in use 12 hours daily needs more frequent service than one used once a week. Usage-based maintenance scheduling ensures equipment gets maintenance when needed, not just when time passes.

This principle applies across many industries. In aviation, aircraft engines require inspection after specific numbers of flight hours. In manufacturing, cutting tools need replacement after processing a certain number of parts. These meter-based triggers are typically determined through extensive testing and real-world performance data.

Used For

• Vehicles monitoring mileage-based maintenance
• Production equipment with cycle-based wear
• Machines with hour meters or usage counters
• High-value assets requiring precise maintenance timing

Pros

• Matches maintenance to actual equipment use
• Reduces unnecessary maintenance work
• Improves parts replacement timing
• Supports more efficient resource allocation

Risk-Based Maintenance 

Maintaining equipment based on potential risks and consequences drives smarter maintenance decisions. Teams evaluate each asset by considering how equipment failure would affect safety, production and costs. A machine that could cause facility-wide shutdowns receives more attention than one with minimal operational impact.

Analyzing risk factors helps maintenance teams allocate resources where they are most needed. As an example, a critical pump system feeding multiple production lines demands closer monitoring than a standalone packaging machine. Understanding these risk levels allows managers to create maintenance schedules that protect their most important assets.

Used For

• Safety-critical equipment and systems
• Production bottleneck machinery
• Environmental protection systems
• High-consequence failure points

Pros

• Focuses resources on crucial equipment
• Reduces serious failure risks
• Supports smarter budget allocation
• Improves maintenance prioritization

Condition-Based Maintenance 

Condition-based maintenance involves using modern sensors and condition monitoring equipment that help maintenance teams track asset health in real time. Instead of relying on schedules or meters, technicians watch for temperature, vibration, noise levels or performance changes that might signal developing problems. Machine data guides maintenance timing, helping teams spot issues before they cause breakdowns.

Real-world performance indicators reveal exactly when equipment needs attention. A motor drawing more power than normal might indicate bearing wear, while unusual vibrations could signal misalignment. Monitoring these conditions lets maintenance teams fix small problems before they grow into major failures.

Used For

• Complex machinery with sensors
• Equipment with measurable performance metrics
• Assets where failure signs are detectable
• Systems requiring precise monitoring

Pros

• Prevents unnecessary maintenance
• Catches problems early
• Reduces unexpected failures
• Makes maintenance more precise

Predictive Maintenance 

Predictive maintenance (PdM) uses advanced data analytics to transform equipment readings into actionable maintenance forecasts. Machine learning algorithms analyze performance patterns, maintenance history and operating conditions. They use this information to predict when failures might occur. Teams use these predictions to schedule repairs before problems develop.

The technology relies on established engineering principles and statistical methods. For example, vibration analysis can detect specific frequencies that indicate bearing wear, while thermal imaging can identify electrical connections that are becoming loose or overloaded. These diagnostic techniques have been refined through decades of industrial application and research.

Accurate failure predictions help managers prevent production losses and reduce maintenance costs. Using pattern analysis, for instance, might show that specific vibration changes typically precede bearing failures in three weeks. With this knowledge, teams can order spare parts and schedule maintenance during planned downtime rather than dealing with sudden breakdowns.

Used For

• Connected equipment with data history
• Machines with clear failure patterns
• Critical production equipment
• Assets with high replacement costs

Pros

• Maximizes equipment reliability
• Plans maintenance efficiently
• Eliminates surprise failures
• Optimizes maintenance spending

Prescriptive Maintenance 

Prescriptive maintenance takes the methods used in predictive maintenance and goes a step further. It uses a combination of real-time data, advanced analytics and machine learning algorithms (artificial intelligence) to predict when an asset needs maintenance and what the best course of action should be to improve operating conditions. 

Smart maintenance platforms that recommend specific actions based on equipment performance data typically integrate with existing computerized maintenance management systems (CMMS) and enterprise resource planning (ERP) software to provide comprehensive oversight of maintenance operations. Using these recommendations, teams decide when and how to maintain their equipment.

Advanced algorithms create detailed maintenance plans tailored to each situation. When a machine shows early warning signs, the system might recommend immediate minor repairs to prevent major problems, or it could suggest waiting if the risk remains low and technicians are handling more urgent tasks. These smart suggestions help maintenance teams work more efficiently.

Used For

• Integrated maintenance systems
• Large equipment fleets
• Operations with multiple variables
• Complex maintenance scheduling

Pros

• Provides clear action steps
• Balances maintenance priorities
• Improves decision-making
• Automates maintenance planning

Example of Preventive Maintenance in Action

Preventive maintenance is a major contributing factor to Toyota’s manufacturing success, helping it set industry standards for equipment reliability. Studies show that when unplanned downtime occurs, companies lose an average of $260,000 per hour, but Toyota’s lift truck plant maintains an impressive 97 percent machine uptime rate through their preventive maintenance process.

Toyota’s plant in Georgetown, Ky., produces 2,000 vehicles daily. Machine operators perform routine maintenance checks every four hours, following detailed maintenance checklists. Maintenance teams analyze performance data weekly and schedule repairs during planned downtime. Instead of waiting until a component fails, technicians replace it during scheduled maintenance windows to avoid disruptions. 

Through targeted steps, small manufacturers can adopt similar strategies. Make sure operators perform regular inspections, create machine-specific checklists and use simple tracking systems. With minimal investment, systematic equipment monitoring reduces unexpected breakdowns, extends machine lifespan and improves operational efficiency.

Industries That Benefit From Preventive Maintenance 

In multiple industries, preventive maintenance is essential to maintaining operational efficiency and reducing equipment failures and emergency repairs. Statistical analysis shows that more preventive maintenance leads to longer equipment lifespans and more reliable operations.

Manufacturing

Manufacturing facilities see direct results from preventive maintenance through increased production uptime. Maintenance teams have to monitor machinery, HVAC systems and conveyor belts every day. Scheduled maintenance prevents costly delays and minimizes mean time to repair (MTTR) when failures occur. Statistical analysis shows that more preventive maintenance correlates with longer equipment lifespans and a more consistent production schedule.

Oil & Gas

Oil and gas operations depend heavily on equipment reliability, particularly for remote offshore equipment. It’s important to monitor and maintain pumps, compressors and pipelines to prevent environmental disasters. Using a predictive maintenance system reduces unnecessary inspections while maintaining safety standards and production targets in hard-to-reach places. Research shows that systematic maintenance extends the life of equipment and prevents costly emergency repairs.

Transportation

Transportation companies maintain large fleets of vehicles and support equipment. According to the Federal Motor Carrier Safety Administration, poorly maintained carriers have a 65 percent higher crash rate than the national average. Key components like brakes, lights, mechanical systems and load securement need maintenance. Airlines perform scheduled maintenance between flights, while trucking companies perform mileage-based maintenance. Preventive maintenance extends the time between repairs, increases fleet reliability and reduces emergency service needs.

Healthcare

Healthcare facilities maintain strict maintenance schedules to protect patient care. Keeping hospital equipment sterile and ensuring patient safety requires regular maintenance of everything from HVAC systems to medical devices. With facilities handling high volumes of examinations and screenings (60 percent of visits) and laboratory testing (40.5 percent of visits), properly maintained equipment is crucial. Preventive maintenance helps providers meet regulatory requirements while reducing emergency repairs and equipment downtime.

Facility Management

Preventive maintenance ensures tenant satisfaction and optimizes asset performance for commercial facility managers. Maintenance of critical systems, like elevators, HVAC, plumbing, electrical and lighting, prevents tenant complaints. Statistical evidence shows that systematic preventive maintenance extends equipment life expectancy and reduces repair frequency. A well-maintained building retains tenants for longer and commands higher rents, while also requiring fewer emergency repairs.

How CMMS Software Can Help Track Preventive Maintenance 

Different types of preventive maintenance software streamline the planning and monitoring of upkeep tasks. A computerized maintenance management system (CMMS) like Coast sends automatic notifications when equipment needs service, helping teams stay on schedule without constant manual checking. Managers can quickly assign work orders and check completion status.

Mobile access lets technicians view maintenance routines, equipment history and parts information right from their phones. They can update work orders, add notes and document completed tasks immediately. Real-time updates keep everyone informed about maintenance progress.

Growing businesses can manage all types of preventive maintenance with Coast’s CMMS solution. Using the system, teams can schedule recurring maintenance tasks, track service history, inventory parts and document maintenance procedures.

Ready to strengthen your maintenance operations? Sign up for a one-on-one demo today.