When it comes to maintenance, there are many approaches and philosophies. But which maintenance advice should plant managers follow to avoid downtime and keep equipment running optimally? Our expert shares some advice.
 

Courtesy: Teadit
Learning Objectives

• Understand the best practices for maintenance strategies.
• Learn how to implement condition-based maintenance strategies.
• Determine how data-based insights are impacting maintenance strategies.

 
Maintenance Insights

• Data-backed insights have opened a new world for reliability-centered maintenance upgrades, requiring up-and-coming engineers to have a keen knowledge of this data.
• Documentation is critical, especially given the manufacturing skill and labor shortage.

• The manufacturing industry is making strides toward standardizing maintenance procedures.

 
Maintenance is a critical function in any plant. But what are the best approaches? Javier Martinez, sales engineering with Teadit, shared some valuable insights to help plant managers better prioritize maintenance.
 
Question: What assets in your plant have benefited most from condition-based maintenance?
 
Answer: Heat exchangers have realized significant benefits from implementing condition-based maintenance strategies. Given the substantial capital investment required to replace this equipment, proactive monitoring and predictive maintenance practices are essential. By identifying performance degradation early, these approaches help maintain optimal operating efficiency, reduce unplanned downtime and minimize the risk of costly repairs or premature replacement.
 
Question: How has the skilled labor shortage changed the way you approach maintenance planning?
 
Answer: The skilled labor shortage has prompted organizations to adopt a more collaborative and strategic approach to maintenance planning. Many now place greater reliance on experienced vendors who can provide hands-on training, onsite consultations and ongoing technical support. This partnership model helps bridge internal resource gaps while ensuring that maintenance activities are executed safely, efficiently and in alignment with best practices.
 
Question: What types of equipment are you most comfortable monitoring or diagnosing remotely?
 
Answer: I am most comfortable with remotely monitoring and diagnosing heat exchangers. These assets have become increasingly predictable in recent years, largely due to advancements in gasket technology and a deeper understanding of bolt relaxation behavior during high temperature service. Enhanced material performance data and improved analytical methods have strengthened our ability to assess joint integrity, anticipate performance trends and identify potential issues before they escalate.
 
Question: Are original equipment manufacturers (OEMs) doing enough to design equipment with maintenance teams in mind?
 
Answer: From my experience, there has been a noticeable reduction in the volume and complexity of technical inquiries about newer equipment compared to legacy systems. This suggests that OEMs are placing greater emphasis on design standardization and documentation quality. The consistency in equipment construction, along with the improved precision and clarity of engineering drawings, reflects a more structured and maintenance-conscious design approach.
 
Question: How has reliability centered maintenance evolved with modern data and analytics?
 
Answer: Reliability centered maintenance has evolved significantly with the integration of modern data collection and analytics tools. As a new generation of professionals enters the industry, there is an increased emphasis on leveraging data-driven insights to support maintenance decision-making and long-term asset performance strategies.
 
From a manufacturer’s perspective, we have made substantial investments in collecting, analyzing and validating performance data across a wide range of applications. This information is shared with our customers to help them make informed, reliability centered maintenance upgrades to existing equipment. By combining field experience with empirical data, organizations are better positioned to optimize maintenance intervals, reduce unplanned downtime, and improve overall operational efficiency.
 
Question: What challenges have you faced in standardizing maintenance procedures across shifts or sites?
 
Answer: There is definite pushback when implementing any change in this industry. The industry is making strides toward standardizing procedures. For example, we have customers who ask us to help them implement and standardize their bolt-up procedure.
 
Question: What does it realistically take to move a plant from reactive to proactive maintenance?
 
Answer: Shifting from reactive to proactive maintenance often requires a significant catalyst, frequently an adverse event that highlights weaknesses in existing practices. In response, organizations reassess safety standards and maintenance procedures, leading to sitewide improvements.
 

Courtesy: Teadit
 

Courtesy: Teadit
 
Question: What tools have had the biggest impact on maintenance planning and scheduling?
Answer: As a vendor, I try to be as involved as possible with maintenance groups. Especially when large turnaround events are being planned years in advance. A clear, effective line of communication between the site and its vendors is crucial to the site’s operations.
 
Question: What strategies are working to capture tribal knowledge before experienced workers retire?
 
Answer: I have noticed an increase in technical training courses offered by manufacturers and in mentorships at end user sites. In addition to investing in local community colleges, colleges have partnered with OEMs to incorporate their specialized knowledge into these courses, so students gain some hands-on experience before joining the workforce.
 
Question: What’s the biggest challenge in optimizing spare parts inventory without increasing downtime risk?
 
Answer: The primary challenge is striking the right balance between reducing inventory costs and maintaining operational readiness. While lowering stock levels can improve working capital, it can also increase exposure to unplanned downtime if critical components are not immediately available.
 
One practical approach is to partner with suppliers that offer consignment inventory programs. This allows essential spare parts to remain on site while payment is deferred until the parts are used. Consignment arrangements are especially valuable during turnarounds and capital projects, where timely access to critical components directly impacts schedule and uptime.
 
Question: How are increasing compliance and documentation requirements affecting maintenance teams?
 
Answer: From my experience, maintenance teams are almost always short-staffed, so when new documentation requirements arise, this strains the team’s effectiveness. As a vendor, I proactively provide my customers with all the necessary documentation I know they will need, and I retain a record if they request it years later.