I've seen those in a reactive environment attempt to jump-start a proactive maintenance mode by adding manufacturer recommended PM's in bulk, and/or by adding a PdM program. However, if the fundamentals aren't in place, PM, PdM, and other programs will likely have limited success. (1) Early problem detection and identification is critical and essential for being proactive. Therefore, when problems are detected, ensure WO's are entered. Then, (2) plan and (3) schedule them in advance. (4) Ensure proper work execution and capture the history. (5) Analyze historical data for CPI (Continuous Process Improvement).
These are the Fundamentals of Maintenance. ENSURE the fundamentals are firmly established and practiced before adopting other strategies or you will not see your maintenance costs decrease or improvements in uptime. Therefore, the investment in a new strategy will only ensure maintenance costs increase through the investment itself. If the fundamentals are in place, a good starting point is to analyze equipment history. Find the "bad actors" (by cost, number of failures, etc...) Look at known failure modes and failure rates. Determine and eliminate the root cause for those failures where possible. Establish the best method of early detection for the failure modes; whether it's PdM, PM, operator rounds, etc... Establish a frequency that will allow early detection.
Plan and schedule the proactive work. Ensure that it is done as-planned and on-schedule. Today's neglected proactive work becomes tomorrow's emergency work.
Tip provided by Jeromy Risner, CMRP, AssetPoint