Manufacturing News

Is preventive maintenance worth it?

February 3, 2005
/ Print / Reprints /
/ Text Size+

According to a survey conducted by Intentia, many companies still question whether preventive maintenance is worth the cost and effort. Nearly 68 percent of the respondents say they allocate less than half of their maintenance budgets for preventive activities that reduce equipment failure and plant shutdown.

The survey investigated maintenance practices within the food and beverage, power, infrastructure and utilities, manufacturing and pharmaceutical sectors. According to the findings, more than 85 percent of the respondents agreed that preventive maintenance increases production and operations capacity, with almost two-thirds reporting that preventive maintenance gives them a competitive advantage.

"These findings suggest disparity between the value of preventive maintenance and the actual commitment of sufficient resources to these needs," said Brian Dunks, enterprise asset management industry solutions director at Intentia. "As a result, many businesses are failing to take advantage of one of the few remaining untapped areas that can directly benefit bottom line performance."

Half of the respondents said they could limit their average annual cost for lost production to $50,000 as a result of plant or equipment failure. Almost seven percent of the companies reported an annual loss of production in excess of $1 million. These losses do not reflect downtime which can include scrap, lost customers, higher unit costs and additional labor and utility overheads.

For many businesses, a planned maintenance strategy is critical to reducing equipment failure and downtime, meeting industry safety requirements and ensuring business continuity and plant availability in order to maximize productivity and profitability.

Many organizations experience challenges to successful maintenance operations. For example, 33 percent of respondents indicated that poor comprehension of maintenance problems by line managers is a key issue. Sixteen percent of respondents indicated lack of funding as a major issue. Poor capital purchasing, management techniques and staff shortages were also contributing factors in getting changes to maintenance practices in place.

For more information about Intentia's 2004 global enterprise asset management benchmarking survey, visit

Did you enjoy this article? Click here to subscribe to Food Engineering Magazine.

You must login or register in order to post a comment.



Image Galleries

Plant of the Year 2014

Blue Diamond Growers was chosen as Food Engineering's 2014 Plant of the Year. The Sacramento-based company is the world’s largest producer of almonds and almond ingredients.


Burns & McDonnell project manager RJ Hope and senior project engineer Justin Hamilton discuss the distinctions between Food Safety and Food Defense as well as the implications for food manufacturers of the Food Safety Modernization Act.
More Podcasts

Food Engineering

Food Engineering December 2014 Cover

2014 December

In the December 2014 issue of Food Engineering read about our Fabulous Food Plant feature on the Chelten House, a new facility in Las Vegas.

Table Of Contents Subscribe

FSMA Audit

What is the is most important step you have taken to become ready for a FSMA audit?
View Results Poll Archive


Food Authentication Using Bioorganic Molecules

This text provides critical tools and data needed to augment routine food analysis and enhance food safety by aiding in the detection of counterfeit, and potentially deleterious, foods.

More Products

Clear Seas Research

Clear Seas ResearchWith access to over one million professionals and more than 60 industry-specific publications,Clear Seas Research offers relevant insights from those who know your industry best. Let us customize a market research solution that exceeds your marketing goals.


FE recent tweets

facebook_40.pngtwitter_40px.pngyoutube_40px.png linkedin_40px.pngGoogle +

Food Master

Food Master Cover 2014Food Master 2014 is now available!

Where the buying process begins in the food and beverage manufacturing market. 

Visit to learn more.