The difference between preventive maintenance and active maintenance in the machining of precision mechanical parts

Preventive and proactive maintenance terminology and language in the machining of precision machined parts are very important in the industry. Saying the wrong thing can have wildly different results, depending on how it's interpreted. That's why it's so important to clarify terms that are often used interchangeably, such as preventive maintenance and proactive maintenance. Sure, they sound similar and are often related to each other, but they are actually two different concepts with unique meanings.

Definitions Matter

Preventive maintenance in the machining of precision machined parts is a periodic maintenance used to prevent failures that lead to downtime. For example, technicians lubricate bushings on machines every eight weeks. These tasks are executed at regular intervals or when certain parameters are triggered. Services are delivered on a predetermined schedule regardless of when or why.

Active maintenance (also known as predictive maintenance) in the machining of precision machined parts is a little different, but the principles remain the same. Maintain assets to prevent failure, not react to it. But proactive maintenance is slightly smarter - it encourages asset maintenance based on accumulated data. For example, bushings on machine X are replaced every Y days because historical data shows that they fail after an average of Z times.

Break down the differences

Still confused? Don't worry, there are a lot of nuances between these two definitions and several other things that separate them.

Preventive maintenance can be performed whether or not it is required. This is the 'safer than sorry' philosophy. As a result, the costs associated with preventive maintenance are usually higher. You can replace flawless parts without wear just because of a maintenance program. You avoid the threat of failure and downtime, but at the same time waste that portion of the remaining life.

Done right, active maintenance during the machining of precision mechanical parts is the solution to this waste. Instead of using a fixed schedule, proactive maintenance uses available data to make fixes as close to the failure as possible (within safe limits) before downtime actually occurs. Based on X years of operational data and a smart sensor, you know there are about Y days left before Part Z fails. You can milk the entire life of the part and still avoid downtime. The problem here is accuracy. If you are correct, proactive maintenance is possible. If not, it will create more problems for itself.

Both methods can be solved

Like all manufacturing methods, the answer to good maintenance comes from a combination of two philosophies.

Preventive maintenance during the machining of precision machined parts has a low chance of causing downtime on equipment and parts that have a limited lifespan and are often inexpensive. Proactive maintenance works well for major components for which decision data is available. This tandem approach strikes a balance between maintenance effectiveness and overall cost. Maintenance technicians just need to be aware of the drawbacks of both methods and understand how their maintenance methods affect the overall performance and output of the machine.