{"id":22204,"date":"2024-10-21T09:59:38","date_gmt":"2024-10-21T15:59:38","guid":{"rendered":"https:\/\/limblecmms.com\/?p=22204"},"modified":"2025-05-30T13:00:25","modified_gmt":"2025-05-30T19:00:25","slug":"usage-based","status":"publish","type":"post","link":"https:\/\/limblecmms.com\/blog\/usage-based\/","title":{"rendered":"Usage-based maintenance: maximizing equipment uptime"},"content":{"rendered":"<p><span style=\"font-weight: 400;\">Usage based maintenance (UBM) is reshaping preventive maintenance strategies in industries all over the world. Because technology is allowing facility managers to see the performance of their equipment in real-time, they can increase the precision of maintenance work.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">UBM is an alternative to some of the more traditional ways of proactively scheduling maintenance. When organizations service machinery based on actual usage, they use their resources more wisely, experience less downtime, and extend asset lifespan and performance. If you&#8217;re striving for operational excellence in your business, mastering UBM is essential for effective asset management and navigating today&#8217;s complex, technology-driven maintenance landscape.<\/span><\/p>\n<h2><span style=\"font-weight: 400;\">What is usage-based maintenance?<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Usage-based maintenance (UBM) is a preventative maintenance strategy that triggers maintenance activity based on how much an asset has actually used since its last upkeep, rather than pre-determined time intervals or calendar-based triggers. To achieve UBM, your maintenance plan will rely on key attributes and data such as:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Operating hours<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Production cycles<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Mileage<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Energy consumption<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">UBM adapts to conditions that actually occur on your factory floor. This is different than traditional planned maintenance or time-based maintenance that follows predetermined schedules you set regardless of how much your equipment gets used. UBM differs from <\/span><a href=\"https:\/\/limblecmms.com\/strategies\/condition-based-maintenance\/\"><span style=\"font-weight: 400;\">condition based maintenance (CBM)<\/span><\/a><span style=\"font-weight: 400;\">, in which maintenance teams take action based on the health of equipment, which is often determined based on sensors, meters, or other condition monitoring devices.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">UBM prevents maintenance teams from being either too cautious or too active. Workers can perform maintenance activities when they\u2019re truly needed instead of intervening prematurely or taking too long and running into unexpected breakdowns. Not every piece of equipment is used the same way or at the same rate, and UBM lets you tailor your <\/span><a href=\"https:\/\/limblecmms.com\/strategies\/\"><span style=\"font-weight: 400;\">maintenance strategy<\/span><\/a><span style=\"font-weight: 400;\"> for each item and better manage your team&#8217;s workload.\u00a0<\/span><\/p>\n<h2><span style=\"font-weight: 400;\">How usage-based maintenance works<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Collecting data and analyzing <\/span><a href=\"https:\/\/limblecmms.com\/blog\/8-essential-asset-maintenance-kpis\/\"><span style=\"font-weight: 400;\">key metrics<\/span><\/a><span style=\"font-weight: 400;\"> on a continuous basis is the foundation of UBM, paving the way for <\/span><a href=\"https:\/\/limblecmms.com\/strategies\/predictive-maintenance\/\"><span style=\"font-weight: 400;\">predictive maintenance<\/span><\/a><span style=\"font-weight: 400;\">. The process begins with establishing usage thresholds for each piece of equipment, which is often derived from manufacturer recommendations or performance and maintenance history. Also, technology that facilitates maintenance triggers is key to implementing effective UBM:<\/span><\/p>\n<ol>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><a href=\"https:\/\/limblecmms.com\/blog\/iiot-maintenance\/\"><span style=\"font-weight: 400;\">Internet of Things (IoT) sensors<\/span><\/a><span style=\"font-weight: 400;\"> monitor equipment usage in real time<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><a href=\"https:\/\/limblecmms.com\/cmms\/\"><span style=\"font-weight: 400;\">Computerized Maintenance Management Systems (CMMS)<\/span><\/a><span style=\"font-weight: 400;\"> track and analyze collected data<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Automated systems generate <\/span><a href=\"https:\/\/limblecmms.com\/blog\/maintenance-work-orders\/\"><span style=\"font-weight: 400;\">work orders<\/span><\/a><span style=\"font-weight: 400;\"> when thresholds are reached<\/span><\/li>\n<\/ol>\n<p><span style=\"font-weight: 400;\">As equipment approaches its predetermined usage limit, the maintenance management system triggers notifications to the maintenance team. This proactive and streamlined approach lets technicians schedule and prepare for the maintenance tasks to come, which makes disruptions to operations less likely.\u00a0\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">As for CMMS, this maintenance software is generally the hub of all your activity, taking data from various sources and giving you a view of the overall state of your equipment. With it you can:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Visualize usage trends<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Adjust thresholds and maintenance triggers as needed<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Use maintenance history to forecast the tools and parts needed for upcoming maintenance<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Generate reports in order make more informed decisions<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">These tools can help your team create a dynamic workflow that more efficiently responds to actual equipment needs, rather than servicing equipment based on an arbitrary timeframe or blind schedule.<\/span><\/p>\n<h2><span style=\"font-weight: 400;\">Benefits of usage-based maintenance<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Usage based maintenance offers numerous advantages that help you go beyond simple <\/span><a href=\"https:\/\/limblecmms.com\/strategies\/reactive-maintenance\/\"><span style=\"font-weight: 400;\">reactive maintenance<\/span><\/a><span style=\"font-weight: 400;\">, and can significantly improve your bottom line and operational efficiency.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">1. Cost savings<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">By performing maintenance only when specific machinery needs it, UBM reduces the risk of unexpected <\/span><a href=\"https:\/\/limblecmms.com\/blog\/equipment-failure\/\"><span style=\"font-weight: 400;\">equipment failure<\/span><\/a><span style=\"font-weight: 400;\"> and <\/span><a href=\"https:\/\/limblecmms.com\/maintenance-definitions\/unplanned-downtime\/\"><span style=\"font-weight: 400;\">unplanned downtime<\/span><\/a><span style=\"font-weight: 400;\">, while also avoiding expenses related to unnecessary parts replacement or <\/span><a href=\"https:\/\/limblecmms.com\/blog\/maintenance-cost-explained\/\"><span style=\"font-weight: 400;\">maintenance costs<\/span><\/a><span style=\"font-weight: 400;\"> involved with performing too much labor. This targeted approach often leads to fewer maintenance expenses overall and better resource allocation.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">2. Improved regulatory compliance<\/span><\/h3>\n<p><a href=\"https:\/\/limblecmms.com\/blog\/achieve-osha-compliance-and-ace-audits-with-cmms-software\/\"><span style=\"font-weight: 400;\">Industry regulations<\/span><\/a><span style=\"font-weight: 400;\"> are always evolving, but UBM helps organizations stay ahead of it by providing detailed usage and <\/span><a href=\"https:\/\/limblecmms.com\/blog\/maintenance-history-records\/\"><span style=\"font-weight: 400;\">maintenance records<\/span><\/a><span style=\"font-weight: 400;\">. This makes audits easier and reduces insurance premiums. It also shows you&#8217;ve been dutiful in maintaining the integrity of the equipment over time, reducing risk of accidents or legal issues.\u00a0<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">3. Tailored performance<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">UBM helps you fine tune the performance of an individual piece of equipment based on its characteristics and how it is used. Consider factors like environmental conditions, operator expertise, or how often you need to use the machinery, and then make changes to settings or frequency of maintenance. By adapting to each asset&#8217;s unique circumstances, UBM enhances the quality of the product you put out, helping you produce more of it with greater consistency.<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">4. Enhanced sustainability practices<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">UBM contributes to environmental sustainability by optimizing resources. When you perform maintenance only when necessary, the organization consumes fewer unnecessary parts, minimizes waste from replacing items prematurely, and lowers energy consumption associated with excessive maintenance.\u00a0<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">5. Improved equipment performance<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">Every maintenance cycle turns into a learning opportunity. As maintenance technicians gather more data, you&#8217;ll find ways to tweak how your equipment runs, often discovering new capabilities you didn&#8217;t know existed. This ongoing process helps your assets perform better and last longer than you might have expected.<\/span><\/p>\n<h2><span style=\"font-weight: 400;\">Steps for setting up usage-based maintenance<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Making the leap to a UBM program involves several stages and each is important if you want to get the job done right. Here&#8217;s a roadmap to guide your organization through the process:<\/span><\/p>\n<ol>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Assess whether you&#8217;re ready:<\/b><span style=\"font-weight: 400;\"> How are you currently evaluating your equipment? Are there any gaps in your <\/span><a href=\"https:\/\/limblecmms.com\/maintenance-definitions\/routine-maintenance\/\"><span style=\"font-weight: 400;\">routine maintenance<\/span><\/a><span style=\"font-weight: 400;\"> and data collection capabilities? Figure out which assets are the prime candidates for UBM based on <\/span><a href=\"https:\/\/limblecmms.com\/blog\/how-to-perform-criticality-analysis\/\"><span style=\"font-weight: 400;\">how important they are<\/span><\/a><span style=\"font-weight: 400;\"> to your operations or their usage patterns.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Develop a pilot program:<\/b><span style=\"font-weight: 400;\"> Select a small number of items for UBM implementation. These case studies let you test and refine processes before using them on a wider scale in your <\/span><a href=\"https:\/\/limblecmms.com\/blog\/preventive-maintenance-program\/\"><span style=\"font-weight: 400;\">preventive maintenance program<\/span><\/a><span style=\"font-weight: 400;\">.\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Set up unique ways to see how each machine is used: <\/b><span style=\"font-weight: 400;\">For instance, with an air compressor, count how many times it turns on and off. For a truck, track both how many miles it&#8217;s driven and how many hours the engine has been on. This gives you a more accurate picture of the <\/span><a href=\"https:\/\/limblecmms.com\/maintenance-definitions\/wear-and-tear\/\"><span style=\"font-weight: 400;\">wear and tear<\/span><\/a><span style=\"font-weight: 400;\"> for each asset.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Create flexible maintenance protocols:<\/b><span style=\"font-weight: 400;\"> Streamline <\/span><a href=\"https:\/\/limblecmms.com\/blog\/standard-operating-procedure-sop\/\"><span style=\"font-weight: 400;\">maintenance procedures<\/span><\/a><span style=\"font-weight: 400;\"> based on usage. For example, you can assign a more experienced technician for certain scenarios, or do a lighter, quicker checkup for equipment that needs less upkeep.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Use feedback to continually refine your approach:<\/b><span style=\"font-weight: 400;\"> Set up regular review meetings with operators, technicians, and managers to gather insights on the UBM program&#8217;s effectiveness.\u00a0<\/span><\/li>\n<\/ol>\n<h2><span style=\"font-weight: 400;\">Embracing the Future of Maintenance<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">UBM is changing preventive maintenance plans in many industries, making organizations smarter and more efficient. As technology advances, UBM will become an important stepping stone to leveraging tools like AI, helping teams improve the precision of their maintenance programs. Companies adopting UBM are positioned as future leaders in and will inevitably have an edge in the marketplace.\u00a0<\/span><\/p>\n<p><a href=\"https:\/\/limblecmms.com\/contact-us\/\"><span style=\"font-weight: 400;\">Schedule a free demo today<\/span><\/a><span style=\"font-weight: 400;\"> to learn more about implementing UBM backed by modern maintenance management technology.<\/span><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Usage based maintenance (UBM) is reshaping preventive maintenance strategies in [&hellip;]<\/p>\n","protected":false},"author":77,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[398],"tags":[],"class_list":["post-22204","post","type-post","status-publish","format-standard","hentry","category-preventive-maintenance"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v25.7.1 (Yoast SEO v25.7) 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