Preventive · Intermediate

Create a Usage-Based Maintenance Plan

Learn how to prepare a maintenance plan based on equipment usage, such as operating hours or kilometres. Define the usage interval and counter reference needed before configuring the plan in ManWinWin.

Usage-Based Maintenance (UbM) is a crucial strategy in asset management, optimizing maintenance interventions based on actual equipment usage rather than fixed calendar schedules. This approach ensures resources are allocated precisely when needed, preventing premature maintenance or unexpected failures. Implementing UbM in your CMMS, like ManWinWin, directly contributes to improved asset reliability and cost efficiency.

Where it's available and step by step

Step by step in ManWinWin Desktop

1
Identify the maintenance work that the usage-based plan must cover, without creating new tasks or work descriptions in this lesson.
2
Identify the existing equipment counter that measures the relevant usage, and note whether its unit is operating hours, kilometres or another operating unit.
3
Define the maintenance interval in that same unit, clearly distinguishing the interval from the total accumulated counter reading.
4
Establish the starting reference for the interval from the agreed maintenance history or initial service reference; do not automatically treat the latest reading as the start of a new interval.
5
Check the intended threshold with a simple example: a 500-hour interval starting at 2,000 hours gives a target of 2,500 hours, not 500 hours on the counter.
6
Prepare the work, counter unit, interval and starting reference for entry, and obtain the verified plan-creation procedure from support@manwinwin.com before configuring and saving the plan.

Theory and technical background

Understanding Usage-Based Maintenance (UbM)

Usage-Based Maintenance (UbM), often a subset of Preventive Maintenance, triggers work orders when an asset reaches a predefined usage threshold, such as operating hours, cycles, or kilometres. This contrasts with time-based maintenance (TBM) which relies solely on calendar intervals. UbM is particularly effective for components whose degradation correlates strongly with operational use, offering a more precise and economical approach than TBM by maximizing component life without increasing breakdown risk. It aligns with ISO 55000 principles of optimizing asset value.

The Role of Equipment Counters in UbM

Accurate and reliable equipment counters are fundamental to successful Usage-Based Maintenance. These devices measure the actual operational output or activity of an asset, providing the essential data for triggering maintenance tasks. Whether mechanical, electrical, or software-based, the counter must be correctly calibrated and regularly monitored. Integrating these counter readings directly into your CMMS, as supported by ManWinWin, ensures that the system has real-time data to automatically generate work orders when specified usage thresholds are met, enhancing responsiveness and efficiency.

Defining Intervals and Starting References

Establishing the correct maintenance interval and its starting reference is critical for UbM plans. The interval defines how often maintenance should occur in terms of usage units (e.g., every 500 operating hours). The starting reference, which might not be zero, dictates the initial point from which the interval is calculated against the total accumulated usage. For example, if an engine requires maintenance every 200 hours and was last serviced at 2,000 total hours, the next target is 2,200 hours. This precision prevents common errors and ensures consistent maintenance scheduling.

Best practices

Always verify counter accuracy before setting up UbM plans to ensure reliable triggers.
Distinguish clearly between the maintenance interval and the total accumulated counter reading.
Base your interval starting reference on actual service history, not just the latest reading.
Regularly review and adjust UbM intervals based on actual asset performance and failure data.

Frequently asked questions

What is the key advantage of Usage-Based Maintenance?

UbM optimizes maintenance by performing it only when genuinely needed, based on actual equipment usage. This reduces unnecessary interventions, extends component life, and minimizes maintenance costs, leading to higher asset availability and efficiency compared to time-based schedules.

How do I choose the right counter for my equipment?

Select a counter that accurately reflects the primary degradation driver for the asset, whether it's operating hours, cycles, or distance. Ensure the counter is robust, reliable, and provides data in a unit that can be easily integrated and tracked within your CMMS.

Can UbM be combined with other maintenance strategies?

Absolutely. UbM often works in conjunction with time-based preventive maintenance for tasks less dependent on usage, or with condition-based maintenance (CBM) for predictive insights. A blended strategy provides the most comprehensive and effective asset management approach, leveraging the strengths of each method.

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