Maintenance System

Preventive Maintenance Is Not Preventing Failures

PM tasks are being completed but repeat defects, emergency work, missed deterioration, or poor equipment condition continue.

Engineering decision

Check whether PM tasks target real failure modes, produce usable evidence, trigger action, and are performed at a defensible interval.

Preserve first

Evidence worth collecting before the condition changes

  • Current PM task list and frequencies
  • Repeat failure history
  • Inspection results and defects raised
  • Overdue work and closure evidence
  • Who performs, verifies, and acts on each task
Separate the explanations

Questions that improve the diagnosis

  • Does each task prevent, detect, or manage a known failure mode?
  • Are vague tasks such as 'check machine' producing measurable evidence?
  • Are findings converted into owned corrective actions?
  • Are frequencies based on condition, consequence, manufacturer guidance, or operating experience?
Avoid premature action

What not to conclude too early

  • Adding more PM tasks without removing low-value work
  • Treating task completion percentage as proof of equipment health
  • Closing inspection findings without action ownership