Across industry, many definitions are used when it comes to the different types of maintenance. It can quickly get confusing when people talk about preventive maintenance, condition-based maintenance, or predictive maintenance but actually have something else in mind than you do. Some people get very excited about these definitions and can spend a lot of time on for example disagreeing with what is and what isn’t preventive maintenance. Let’s not do that, instead, I’ll offer you my view of the different types of maintenance and more importantly, when to use them.
What are the types of maintenance?
As far as I am concerned terminology is not important. Other than making sure we are talking about the same thing. If what I consider to be condition-based maintenance you call predictive maintenance that doesn’t really matter. As long as we sensibly talk about the underlying principles.
Like, when to use condition-based maintenance. And how to use it.
However, as I’m often asked questions about the different types of maintenance I decided to put a quick overview together of the types of maintenance.
At least, the way I see it:
There are 9 types of maintenance split between Preventive Maintenance and Corrective Maintenance.
Preventive Maintenance is done before a failure occurs and consists of maintenance types like:
Time-Based Maintenance, Failure Finding Maintenance, Risk-Based Maintenance, Condition Based
Maintenance and Predictive Maintenance.
Corrective maintenance is done after a failure has occurred either as Deferred Corrective Maintenance or as Emergency Maintenance. In the rest of this article, I will discuss each of these different types of maintenance in detail:
Preventive Maintenance (PM)
- Time-Based Maintenance (TBM)
- Failure Finding Maintenance (FFM)
- Risk-Based Maintenance (RBM)
- Condition-Based Maintenance (CBM)
- Predictive Maintenance (PDM)
Corrective Maintenance (CM)
- Deferred Corrective Maintenance
- Emergency Maintenance (EM)
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Preventive Maintenance vs Corrective Maintenance
At the top level, I see maintenance being either preventive or corrective:
- When we do preventive maintenance we are doing a task before a failure has occurred. That task can be aimed at preventing a failure, minimising the consequence of the failure, or assessing the risk of the failure occurring.
- When we are conducting corrective maintenance the failure has now occurred and we are basically reinstating equipment functionality. To be clear, corrective maintenance can be the result of a deliberate run-to-failure strategy.
Preventive Maintenance (PM)
Preventive maintenance can be defined as “an equipment maintenance strategy based on replacing, or restoring, an asset at a fixed interval regardless of its condition. Scheduled restoration tasks and replacement tasks are examples of preventive maintenance tasks.” (source: Reliabilityweb)
Time-Based Maintenance (TBM)
When people talk about preventive maintenance (or preventative maintenance) they usually refer to what is better described as Time Based Maintenance (TBM). Time-Based Maintenance is basically a type of maintenance that is done at a regular interval while the equipment is still functioning with the objective of preventing failure or reducing the likelihood of failure.
Preventive maintenance can be time-based i.e. every week, every month, or every three months. But preventive maintenance can also be based on usage e.g. every 150 cycles, every 10,000hrs, or like your car: service every 10,000km.
Apart from the regular interval approach (time-based maintenance) there are also other types of maintenance that fall within the category of preventive maintenance:
- Time-Based Maintenance (TBM)
- Failure Finding Maintenance (FFM)
- Risk-Based Maintenance (RBM)
- Condition Based Maintenance (CBM)
- Predictive Maintenance (PDM)
In the following paragraphs, I will explore each of these types of maintenance in more detail including when you should consider using them.
Risk-Based Maintenance (RBM)
Risk-Based Maintenance (RBM) is when you use a risk assessment methodology to assign your scarce maintenance resources to those assets that carry the most risk in case of a failure (remembering that risk = likelihood x consequence).
As a result, equipment that has a higher risk and a very high consequence of failure would be subject to more frequent maintenance and inspection. Low-risk equipment may be maintained at a much lower frequency and possibly with a much smaller scope of work.
When you implement a Risk-Based Maintenance process effectively you should have reduced the total risk of failure across your plant in the most economical way.
Risk-Based Maintenance is essentially preventive maintenance where the frequency and scope of the maintenance activities are continuously optimised based on the findings from testing or inspection and a thorough risk assessment. Examples of Risk-Based Maintenance would be Risk-Based Inspection as
applied to static equipment like vessels and piping or even pressure relief valves.
Failure Finding Maintenance (FFM)
Failure Finding Maintenance tasks are aimed at detecting hidden failures typically associated with protective functions. Think pressure safety valves, trips transmitters, and the like. This type of equipment won’t be required to function until something else has failed.
That means that under normal operating conditions you will not know whether this equipment is still functional i.e. the failure modes are hidden. And since these failures are hidden, you’ll need to find them before you are relying on that equipment to protect you.
Simple really.
It’s important to realise that failure-finding maintenance tasks do not prevent failure but simply detect it. And once detected you’ll have to repair the failure you found. Failure Finding Maintenance is conducted at fixed time intervals typically derived from legislation
or risk-based approaches.
Condition Based Maintenance (CBM)
Most failure modes are not age-related. However, most failure modes do give some sort of warning that they are in the process of occurring or are about to occur. If evidence can be found that something is in the early stages of failure, it may be possible to take action to prevent it from failing completely and/or to avoid the consequences of failure.
Condition Based Maintenance as a strategy, therefore, looks for physical evidence that a failure is occurring or is about to occur. Thinking of CBM in this way shows its broader applications outside condition monitoring techniques often only associated with rotating equipment.
An important concept within Condition Based Maintenance is the P-F curve shown in the figure below:
The curve shows that as a failure starts manifesting, the equipment deteriorates to the point at which it can possibly be detected (point “P”). If the failure is not detected and mitigated, it continues until a functional failure occurs (point “F”). The time range between P and F, commonly called the P-F interval, is the window of opportunity during which an inspection can possibly detect the imminent failure and give you time to address it.
It is important to realise that CBM as a maintenance strategy does not reduce the likelihood of a failure occurring through life-renewal, but instead is aimed at intervening before the failure occurs, on the premise that this is more economical and should have less of an impact on availability.
In other words: condition monitoring does not fix machines and condition monitoring does not stop failures. Condition monitoring only lets you find problems before they become a failure.
A common rule of thumb is that the interval between CBM tasks should be one-half or one-third of the P-F interval.
How much more effective CBM is above breakdown maintenance depends on how long the P-F interval is. With plenty of warning the rectification can be planned, materials and resources can be mobilised and breakdown prevented (though production is still stopped for the maintenance duration). When the P-F interval is only a few days the resulting organisational and workplace actions are much like a breakdown and the value of CBM is largely lost.
For CBM to be effective as a strategy, early intervention is essential. This requires an efficient and effective process for data gathering, data analysis, decision making, and finally intervention.
For failure modes where the P-F interval shows a large variability, condition monitoring is not an effective strategy.
If you’re interested to find out more about how to best manage failure modes don’t forget to check out my article Reliability Centered Maintenance – 9 Principles of Modern Maintenance.
Types of maintenance PDF
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Predictive Maintenance (PDM)
Up until recently when people spoke about Predictive Maintenance (PDM) this was essentially as a synonym for Condition Based Maintenance. But with the advent of Artificial Intelligence, much lower costs of equipment sensors (IIoT), and machine learning there is clearly a difference appearing between Predictive Maintenance (PDM) and Condition Based Maintenance (CBM), at least in my view.
I see Predictive Maintenance as an extension, a more advanced approach to CBM where we use potentially many process parameters gained from online sensors to determine if our equipment is moving away from stable operating conditions and is heading towards failure. The central idea here is to predict when the failure is going to occur and then determine the appropriate time for maintenance intervention.
There are a lot of (very large) companies actively moving into this space and it is certainly a fast-moving and exciting part of our discipline as Maintenance & Reliability professionals. However, I do still believe that even the most advanced Predictive Maintenance approaches need to be underpinned by sound reliability principles and understanding. And I also believe that the use of Predictive Maintenance has been hyped up too much across the industry. In most cases it is little more than Condition Based Maintenance, just marketed with a new buzzword.

Corrective Maintenance (CM)
A Run to Failure or Corrective Maintenance strategy only restores the function of an item after it has been allowed to fail. It is based on the assumption that the failure is acceptable (i.e. no significant impact on safety or the environment) and that preventing failure is either not economical or not possible.
Apart from being the outcome of a deliberate Run to Failure strategy Corrective Maintenance is also the result of unplanned failures which were not avoided through preventive maintenance.
A run to failure strategy can effectively be used for general area lighting, smart process instrumentation (without trip functionality) etc. where the consequence of failure is limited and would not necessitate a need for an urgent repair.
When opting for corrective maintenance as a strategy it is essential to ensure that the failure modes under consideration do not have the potential to become Emergency Maintenance. You see if you adopt run-to-failure for equipment that once it has failed must be restored immediately to have doomed your organisation to a reactive maintenance environment. A reactive maintenance environment is not where you want to be. It is more expensive, less
efficient, and less safe.
So although a run-to-failure strategy can be a good option, make sure you decide wisely.
Deferred Corrective Maintenance
In the chart of maintenance types I broke ‘corrective maintenance’ into two sub-types:
- Deferred Corrective Maintenance
- Emergency Maintenance
And that was very deliberate because it is so essential that we absolutely minimize the amount of Emergency Maintenance we allow into our organisations. As I already pointed out above Emergency Maintenance is expensive, various sources have suggested that Emergency Maintenance is 3 to 5 times as expensive as ‘normal’ preventive maintenance.
Emergency Maintenance typically leads to longer equipment outages and more production impact. And it is less safe. So when a corrective maintenance work request is raised it is essential that you prioritise it properly to make sure that where possible you defer the work request and give your team the time to properly plan and schedule the work.
If you want to read more about prioritisation of corrective maintenance have a look at the article You Will Fail Without Planning & Scheduling.

Emergency Maintenance (EM)
Emergency Maintenance is corrective maintenance that is so urgent that it breaks into your Frozen Weekly Schedule (you do have one don’t you?).
It upsets your plans and schedules and typically throws everything into disarray. Some people thrive in this type of environment and often get heralded as heroes when they’ve worked 16hrs non-stop to get production back online. But when it comes to the Road to Reliability it is a dead end.
So Emergency Maintenance is the one and only maintenance type that we really want to avoid as much as possible. In fact, World Class organisations ensure that less than 2% of their total maintenance is Emergency Maintenance. How much Emergency Maintenance do you have?
Types of Maintenance: A comparison
The table below shows a brief summary of:
- The different types of maintenance;
- What type of tasks are involved;
- The objective of the task;
- and How the interval between the tasks is determined.
An efficient and effective Preventive Maintenance Program will have a mix of all these different types of maintenance.
Types of maintenance FAQ
In the rest of the article, I want to answer some of the most Frequently Asked Questions (FAQ) I get from readers or email subscribers.
Let’s start with a classic:
What type of maintenance is the most expensive?
The most expensive type of maintenance is Emergency Maintenance because this is the type of maintenance that is so urgent that you drop everything to run off and fix the problem. That means that Emergency Maintenance is usually not well planned (prepared) and therefore is highly inefficient and expensive (typically at least 3 – 5 times as expensive as well-planned preventive maintenance).
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What is breakdown maintenance?
And frequently asked question is ‘what is breakdown maintenance’ and as it’s not in my explanation I thought I’d just cover it here briefly. As far as I am concerned, breakdown maintenance is simply corrective maintenance and not another type of maintenance in itself. In the case of breakdown maintenance, you’ve had a failure and so now it needs to be fixed.
And depending on the risk associated with that breakdown it could be urgent or less urgent.
But, in many people’s minds, breakdown maintenance is urgent maintenance, maintenance that needs to be done right now i.e. Emergency Maintenance. And if that’s the case for you, you know what to do: get rid of it!

What is the difference between preventive maintenance and predictive maintenance?
I think I have covered this in the article, but as it’s such a frequently asked question I’ll just summarise the key differences here:
- Preventive maintenance covers multiple types of maintenance that are used before a failure has occurred. Predictive maintenance is a form of preventive maintenance.
- When most people talk about preventive maintenance they really mean Time Based Maintenance which is a repair or replacement on a fixed interval irrespective of the condition of the equipment. The interval can be time-based (days, weeks, or months) or usage-based (operating hours, cycles, or km).
Are planned maintenance and preventive maintenance the same?
In my view, they are not the same. Planning refers back to the maintenance planning & scheduling process so planning maintenance is about preparing the maintenance work so that is ready to execute. Whereas preventive maintenance is maintenance that has been identified to prevent or mitigate a failure mode.
So in my view, Planned Maintenance is maintenance that has been through the planning process and is properly prepared with all job steps, labour, parts, and tools identified and organised.
All Preventive Maintenance should be Planned Maintenance as it has been identified upfront and there is no reason why it would not go through the normal maintenance planning & scheduling process.
The opposite of Planned Maintenance is Unplanned Maintenance which has not properly been prepared and is planned on the plan as the job is done. This is highly inefficient and something you should avoid at all cost. The only time you should be conducting unplanned maintenance is when you have a high-priority work request that comes in and is so urgent that you break into the Frozen Weekly Schedule to complete the work without going through the normal planning & scheduling process. I refer to this as Emergency Maintenance.
And what about autonomous maintenance?
The above table of types of maintenance does not include Autonomous Maintenance or Autonomous Care (also referred to as Front Line Maintenance in other organisations). The CLAIR (Clean, Lubricate, Adjust, Inspect, and Repair) activities conducted under Autonomous Care are essentially a combination of the above strategies but conducted on a higher frequency by frontline staff.
Which type of maintenance is most expensive?
This is an interesting question and generally speaking unplanned corrective maintenance i.e. Emergency Maintenance is the most expensive to conduct. This is because this type of maintenance does not go through the full maintenance planning & scheduling process because it’s so urgent and it’s simply planned on the fly. That means when you execute Emergency Maintenance you typically have very low efficiency with additional time wasted looking for materials, organising access to the equipment, waiting on other trades etc. Another common issue with Emergency Maintenance is that often parts and services are expedited to arrive faster and increased costs are incurred to make that happen.

Why is preventive maintenance better than breakdown maintenance?
In general, prevention of a failure is simply a lot cheaper and safer than letting equipment fail. Plus, preventive maintenance would have much less impact on production than breakdown maintenance (i.e. running to failure).
However, there are instances when a deliberate run-to-failure maintenance strategy is the right thing to do. A good example would be something like general area lighting in an industrial plant where you will simply wait till you have a number of lights that have ailed and then you replace them. Trying to replace these lights before they fail would be a waste of money because we cannot accurately predict when lightbulbs will fail. And because the consequence is low we can simply accept that general lighting is run to failure.
Which is better: preventive maintenance or predictive maintenance?
Predictive Maintenance really is a type of Preventive Maintenance as they both see you conducting maintenance before the failure has occurred. The issue is though that most people think of the
traditional Time-Based Maintenance when they talk about Preventive Maintenance.
So from that perspective which is better? Neither. You need to select the right maintenance type based on the failure mode you’re trying to manage and its characteristics.
If you have a failure mode that is random in nature you would want to opt for a condition-based or predictive maintenance task so that you can see the potential failure coming closer and take action before the failure occurs.
But, if you have a failure mode that is very clearly age-related or where a condition-based task is simply not economical then you would use a time-based maintenance task.
Lube oil change out on a turbine with thousands of liters of oil is often best done on condition to ensure you get the maximum life out of the oil. But, if you are only dealing with 50 liters of oil the time and effort it takes to sample the oil and analyse it probably means it’s not worth going condition-based and you simply change that oil out based on a fixed time or fixed number of running hours.
FAQs
How do I choose a maintenance strategy? ›
To develop a maintenance strategy you have to evaluate and weigh the unique benefits and shortcomings of each strategy, depending on what assets you're working with, what stage of the reliability journey your organization is at, and the impact of downtime at your facility.
What are the types of maintenance strategy? ›- Corrective maintenance.
- Preventive maintenance.
- Risk-based maintenance.
- Condition-based maintenance.
Preventive maintenance – includes regular and periodic (time-based) schedules. Corrective maintenance – occurs when an issue is noticed. Predetermined maintenance – follows a factory schedule. Condition-based maintenance – occurs when a situation or condition indicates maintenance is needed.
What is a maintenance strategic plan? ›What is Strategic Maintenance Planning? It is working on the things that improve the plants business condition, not just doing good maintenance. It means making choices about where we focus our time and effort, where we spend our money. It is the business solution that maximizes our limited resources to the fullest.
What type of maintenance is most effective? ›Predictive maintenance is more effective at detecting potential breakdowns than preventive maintenance and is more incisive to which actions are actually needed.
Why do we need maintenance strategy? ›Benefits of optimizing your maintenance strategy include extending asset life, reducing asset failures, minimizing repair costs and improving health and safety. Start by assessing your current maintenance strategy to identify its strengths and weaknesses.
What are the three main types of maintenance requirements for managed properties? ›The three types of property maintenance are preventive maintenance, reactive or corrective maintenance, and predictive maintenance. Preventive maintenance involves regular inspections and upkeep of a property to minimize the need for significant repairs or replacements.
What are the 10 ways of maintaining tools and equipment? ›- Read the User Guide. ...
- Use the Correct Equipment For The Job. ...
- Know Your Machinery. ...
- Inspect Regularly. ...
- Carry Out Regular Maintenance, Using a Schedule. ...
- Replace Parts When Needed. ...
- Clean After Use. ...
- Repair and Refurbish, Rather Than Replace.
- Air conditioning. ...
- Drain clogs. ...
- Broken doors and locks. ...
- Damaged sinks. ...
- Shower. ...
- Lights. ...
- Toilets. ...
- Garbage disposal.
They are purchasing, operator training, technician training, scheduled maintenance, repairs, consumables, fleet sizing and machine disposal.
What is maintenance strategy summary? ›
Maintenance strategy is based on corrective, preventive and condition approaches. Different types of buildings, services and fittings require different types of maintenance approaches. However, the common factors influencing maintenance strategy are health and safety, and are fit for use, law, value and quality.
What are the 8 elements of a strategic plan? ›- Vision statement. The vision statement is an important part of a strategic plan as it provides a short summary highlighting what your business will look like in the future. ...
- Mission statement. ...
- Goals and objectives. ...
- SWOT analysis. ...
- Action plan. ...
- KPIs.
- Define your vision.
- Assess where you are.
- Determine your priorities and objectives.
- Define responsibilities.
- Measure and evaluate results.
An effective plan needs to cover all the features of your facility's maintenance policy. The program should contain an exhaustive inventory of assets that you need to maintain. The list which includes numerous items like boilers, pumps, and roofs, ensures that you don't leave out any vital asset.
What is perfect maintenance? ›Perfective Maintenance means the process of modifying Software or Applications to implement new or changed user requirements which concern functional enhancements.
What is the most important function of maintenance? ›It helps companies maintain their resources while controlling time and costs to ensure maximum efficiency of the manufacturing process, the utilities and related facilities. It is a tool that helps to secure a reliable and satisfactory quality of the production, safety for employees and protection for the environment.
What is the most important relational maintenance strategy? ›Results showed that across all relationship types, assurances were the most used relational maintenance strategy and openness was the least used strategy.
What are rules of maintenance? ›- Planning. Maintenance must start with proper planning. ...
- Making the workplace safe. The work area needs to be secured by preventing unauthorized access, by using barriers and signs, for example. ...
- Use of appropriate equipment. ...
- Working as planned. ...
- Final check.
Still, Asset management, inventory management, work-order management, preventative maintenance, reports/dashboards are the five key characteristics of CMMS solutions.
What are the 7 main factors to be considered when using a power tool? ›- • KEEP WORK AREAS CLEAN. Cluttered benches invite accidents. • AVOID DANGEROUS ENVIORONMENTS. ...
- • GUARD AGAINST ELECTRIC SHOCK. Prevent body contact with. grounded surfaces. ...
- • AVOID ACCIDENTAL STARTING. Don't carry plugged in tool with finger on switch.
What are the 6 basic guidelines in maintaining hand tools and equipment? ›
- Inspect regularly. Regularly inspect your tools to make sure that they are in good condition.
- Wear gloves. ...
- Carry with care. ...
- Don't pocket sharp objects. ...
- Be aware of your surroundings. ...
- Use the right tools. ...
- Follow instructions. ...
- Clean and return.
Time-based maintenance (TBM) is maintenance performed on equipment based on a calendar schedule. This means that time is the maintenance trigger for this type of maintenance. TBM maintenance is planned maintenance, as it must be scheduled in advance.
What are the different types of maintenance problem? ›4 Types of Maintenance Problems. The four common types of maintenance problems can be categorized as identification, cause/effect, means and ends.
What is the example of maintenance? ›Cleaning, visual inspection, functional tests, lubrication, measurement of operating quantities and oil tests are some of the examples of routine maintenance activities.
What are the three 3 main types of maintenance categories? ›- Corrective Maintenance.
- Preventative Maintenance.
- Predictive Maintenance.
- Schedule maintenance according to equipment usage. ...
- Make employees accountable for maintenance. ...
- Ensure that the preventive maintenance tasks being performed are beneficial to the equipment. ...
- Plan ahead to accommodate seasonality. ...
- Ask your equipment provider for a maintenance arrangement.
These key steps are plan, inspect, clean, tighten, lubricate, test, record, and evaluate.
What are the seven 7 basic steps in building effective maintenance management plan? ›- Mean Time Between Failure (MTBF)
- Mean Time To Repair (MTTR)
- Spare part expenditure.
- Machine downtime.
- Equipment usage.
- Technician response time.
There are 4 key types of maintenance management strategies including run-to-failure maintenance, preventive maintenance, predictive maintenance, and reliability-centered maintenance.
What are examples of maintenance services? ›Examples of facilities maintenance include:
General building repairs. Maintenance of building life-safety, and systems such as heating, ventilation, air conditioning, plumbing, electrical and lighting. Pest control. Care of trees and shrubbery, lawns, sidewalks and snow removal.
What is the best preventive maintenance? ›
- Schedule and perform regular inspections of equipment.
- Conduct regular cleaning of buildings, grounds and assets.
- Lubricate moving parts to reduce wear-and-tear.
- Adjust controls for optimal performance and energy efficiency.
- Repair and replace any defective equipment parts.
- Preventive Maintenance Equipment Inspections. ...
- Clean Equipment Regularly to Minimize Dirt and Dust. ...
- Lubricate Rotating Parts to Prevent Premature Wear. ...
- Check Machinery Power to Optimize Energy Efficiency. ...
- Repair or Replace Equipment Before it Fails.
Example tasks may include cleaning, lubrication, replacing or repairing parts, or even partial or complete overhauls. More obvious examples of preventive maintenance include ensuring production line equipment is working efficiently or heating, ventilation or air conditioning elements are inspected, cleaned and updated.
What is main maintenance? ›Major maintenance means an expenditure for maintenance or repair that will result in extending the life of an asset for a period greater than one year.
How many levels of maintenance are there? ›There are 5 levels of maintenance, from the simplest to the most complex. Each level has its own corrective and preventive maintenance actions.
What factor affects choice of a maintenance strategy? ›The main two factors to consider are the cost of equipment failure and the ease of monitoring the equipment. Both will form the basis of your maintenance strategy for each piece of equipment. It is the impact that a failure will have in your business.
What are the five most common relationship maintenance strategies? ›Stafford and Canary (1991) have identified five relational maintenance strategies: assurance, positivity, sharing tasks, social networks, and openness.
Why is it important to have an effective maintenance strategy? ›The idea behind maintenance planning is to ensure that you can sustain the proper working condition of your equipment. While an ordinary plan will get the job done, any facility requires an effective program to enjoy the full benefits of your maintenance policy.
What is the importance of maintenance strategies? ›Benefits of optimizing your maintenance strategy include extending asset life, reducing asset failures, minimizing repair costs and improving health and safety. Start by assessing your current maintenance strategy to identify its strengths and weaknesses.
What are the 7 relational maintenance strategies? ›The measure was labeled the Relational Maintenance Behavior Measure (RMBM), rather than strategies, in order to indicate that these behaviors were not necessarily either strategic or routine. These seven factors were positivity, assurances, shared networks, tasks, self-disclosure, relationship talk, and understanding.
What are the 7 relationship maintenance strategies behaviors? ›
Stafford's new typology included the following maintenance behaviors: positivity, assurances, understanding, relationship talk, self‐ disclosure, social networks, and sharing tasks.
What are three strategies that you can suggest to end a relationship? ›...
These tips may help:
- Prepare. ...
- Pick the right spot. ...
- Say it in person. ...
- Be respectful. ...
- Make a clean break. ...
- Stick with your decision.
Five types of maintenance are in fact recurrent in the industry: corrective, preventive, condition-based, predictive and predetermined.