Preventive Maintenance Scheduling

Reliability-Centered Maintenance (RCM) Engine Asset Criticality Ranking AI evaluates each asset against: production impact (what happens if it fails?), safety impact, environmental impact, repair cost, and replacement lead time. Assigns a criticality tier: Critical / Important / General. This determines the maintenance strategy intensity. Failure Mode Analysis For each Critical asset, AI identifies historical failure modes from maintenance records. Calculates: Mean Time Between Failures (MTBF), Mean Time To Repair (MTTR), and failure probability curves

(Weibull distribution where applicable). Maintenance Strategy Selection Based on failure patterns, AI recommends the optimal strategy per asset: Condition-Based (monitor vibration, temperature, oil analysis), Time-Based (replace every X hours/months), Predictive (AI-driven anomaly detection), or Run-to-Failure (only for non-critical, cheap-to-replace items). PM Schedule Optimization AI generates a maintenance calendar that: balances workload across crews, coordinates with production schedules (maintenance during planned downtime), sequences tasks to

minimize tool changes, and respects parts availability from the storeroom. Total Maintenance Cost Dashboard Track: Planned vs. Unplanned maintenance ratio (world-class: 80/20), PM compliance rate, maintenance cost per unit of production, and spare parts inventory efficiency. AI benchmarks against industry standards. Target an 80/20 planned-to-unplanned maintenance ratio — AI should track this weekly and identify which asset categories are generating the most reactive work orders. Implement condition monitoring on Critical assets: vibration analysis

(rotating equipment), thermography (electrical), and oil analysis (hydraulic/lubrication systems). Track 'PM Compliance' — if scheduled PMs are being deferred because of production pressure, AI should calculate the increased failure probability from each deferral. Don't apply the same maintenance frequency to all assets — a Critical compressor and a General office HVAC unit have wildly different optimal PM intervals. Don't treat maintenance as just cost — calculate the 'Cost of Unplanned Downtime' per hour for each production line. This justifies the PM

investment to finance. Don't hoard spare parts 'just in case' — AI should calculate the optimal stocking level per part based on criticality, lead time, and consumption rate. The 'OEE Integration' Strategy Connect maintenance data with Overall Equipment Effectiveness (OEE). AI can decompose OEE losses into: Availability losses (breakdowns, setup), Performance losses (slow cycles, small stops), and Quality losses (defects, rework). This reveals whether your biggest improvement opportunity is in maintenance (availability), operations (performance), or

quality — focusing resources where they'll have the most impact.