Industrial maintenance is an investment that keeps facilities profitable and productive. When machinery breaks down, the costs go far beyond inconvenience. On average, every hour of unplanned downtime costs a facility around $25,000, with larger manufacturing operations seeing losses beyond $500,000 per hour.
The average manufacturing facility experiences 15 to 20 hours of unplanned downtime every month, making effective industrial maintenance critical for profitability. Industrial maintenance professionals prevent equipment failure with regular inspections and routine upkeep tasks that help machines stay in good working condition. The result is fewer breakdowns, less waste, and more throughput and production capacity. Maintenance is the backbone of industrial operations, working behind the scenes to protect both productivity and the bottom line.
Let's explore what industrial maintenance really involves, including the roles, daily tasks, and strategies that separate good programs from great ones. Whether you're looking to streamline your maintenance strategies or are considering a career in this field, you'll find actionable insights here on how MaintainX helps improve operations and maximize equipment lifespan.
Key takeaways
- Industrial maintenance combines preventive, predictive, and reactive strategies to keep machines running longer and reduce costly breakdowns.
- Key roles in this field range from hands-on maintenance mechanics to strategic maintenance managers, all requiring strong problem-solving and technical skills.
- Setting up a computerized maintenance management system is crucial for modern industrial maintenance, enabling live data tracking, automated scheduling, and streamlined communication.
- Best practices for maintenance management include consistent condition monitoring, detailed asset health reporting, and maintaining a well-organized spare parts inventory to prevent delays.
What is industrial maintenance?
Industrial maintenance covers all the strategies and practices that keep machinery, equipment, and systems running smoothly in industrial settings. By employing the right combination of preventive, predictive, and reactive maintenance techniques, maintenance professionals reduce unexpected outages and extend equipment lifespans. This is critical to maintaining operational efficiency in industries like manufacturing, energy production, and construction industries.
Industrial maintenance today
For decades, the role of maintenance was to fix things once they were already broken. However, today's industrial maintenance teams focus on proactive strategies, preventing breakdowns before they occur so they can increase uptime and make plants more reliable. It ensures all plant assets are in good working condition. For this reason, people sometimes refer to industrial maintenance as plant maintenance.
Industrial settings that practice this category of maintenance include food processing plants, manufacturing facilities, electricity plants, and more. These facilities depend on smart maintenance programs to stay competitive and hit production goals.
Organizations that require industrial maintenance
Any business relying on heavy machinery and regular production benefits from industrial maintenance to keep operations smooth and efficient. The following industries, in particular, depend heavily on regular maintenance to maximize uptime and prevent costly downtime:
- Manufacturing: Electronics factories, furniture manufacturers, paint suppliers, or other organizations producing goods for consumers or businesses.
- Food processing: Plants preparing food and beverages, like SanTan Brewing Co.
- Construction: Companies that construct infrastructure or buildings, such as offices, housing, malls, hotels, and hospitals.
- Automobile: Auto parts manufacturers or assembly plants.
- Aviation: Aircraft manufacturers or assembly plants.
- Electricity production: Fossil-fuel or hydroelectric power stations, nuclear power plants, wind turbines, like South East Power.
Industrial facilities always have maintenance staff on board and typically work in teams. Additionally, companies will sometimes hire contractors for specific complex maintenance tasks.
Careers in industrial maintenance
Industrial maintenance offers a wide range of career paths for those who enjoy solving problems and working with complex machinery. From hands-on technicians to strategic management roles, industrial maintenance professionals are essential to keeping everything running smoothly in every sector. Let's explore some common job roles in this field and the key skills you need to succeed.
Common industrial maintenance jobs
Industrial maintenance offers a variety of roles, each with its own responsibilities and areas of expertise. Some of the most common positions in this field include:
Maintenance manager
Maintenance managers oversee day-to-day maintenance operations and report to upper management. They develop strategic maintenance programs, coordinate scheduling, manage budgets, and ensure compliance with safety regulations and company policies.
Maintenance supervisor
Maintenance supervisors directly oversee technicians' work and ensure they follow maintenance schedules. They also track key performance indicators (KPIs), such as mean time to repair (MTTR), to assess team performance and efficiency.
Maintenance planner
Maintenance planners ensure technicians have the tools, resources, and parts needed to complete maintenance activities. They also help schedule maintenance tasks and align them with production goals.
Maintenance mechanic
Maintenance mechanics specialize in troubleshooting, repairing, and maintaining complex industrial machinery. They often perform preventive maintenance and emergency repairs to keep operations running smoothly.
Industrial engineer
Industrial engineers design efficient systems for maintaining and repairing equipment. While they don't typically perform hands-on maintenance tasks, they play a critical role in improving processes and developing strategies to minimize downtime.
Education and certification requirements
A successful career in industrial maintenance often begins with a combination of formal education and practical experience. Many professionals enter the field with a high school diploma and gain skills through hands-on training or apprenticeships like an industrial maintenance technician program.
An associate's degree in industrial maintenance technology, engineering, mechatronics, or a related field provides a stronger foundation and leads to more advanced positions.
To further advance your career and demonstrate expertise, professionals pursue industry-recognized certifications:
- Certified Maintenance and Reliability Professional (CMRP): Ideal for maintenance managers and supervisors seeking to validate strategic skills
- Certified Maintenance and Reliability Technician (CMRT): Validates hands-on technical skills for maintenance mechanics and technicians
Key skills for industrial maintenance personnel
Industrial maintenance technicians and workers need a broad skill set to manage the variety of tasks required to keep machinery and equipment running efficiently. These skills are critical for anyone looking to build a successful career in industrial maintenance:
Problem-solving
Maintenance work involves identifying and fixing issues with complex machinery and systems. Maintenance employees must be able to identify the best operational solution in the shortest possible time and perform well under pressure. Production interruptions create incredibly stressful situations.
Attention to detail
Technicians should possess a keen eye for detail. This trait is crucial when installing, repairing, and maintaining heavy machinery. An eye for detail is needed to follow manufacturers' guidelines and standard operating procedures (SOPs) with a high level of precision.
Adaptability
Different pieces of equipment require different maintenance strategies. Maintenance workers must be able to adapt quickly from one SOP to the next. SOPs and best practices often change over time, so workers need to stay open to improving their skills and knowledge.
Communication skills
Maintenance teams perform most industrial maintenance work in collaborative settings. Strong communication skills are therefore essential for maintenance personnel. A good CMMS smartphone app with chat functionality streamlines communication within the team.
For example, Ahlstrom Reduced MTTR by 90% through centralized tribal knowledge. In case of emergency maintenance, it helps maintenance skilled technicians coordinate their efforts without information falling through the cracks.
Physical strength and endurance
Finally, maintenance work is often physically demanding. Technicians engage in activities that require endurance, stamina, and strength. Common physically demanding maintenance tasks include carrying and assembling heavy machine parts, climbing tall ladders, and working in unusually hot or cold temperatures.
Examples of industrial maintenance and repair tasks
Examples of specific industrial maintenance tasks include:
- Lubricating equipment with rotating parts.
- Detecting and fixing issues in hydraulic or pneumatic systems.
- Performing maintenance work on boilers, heat exchangers, and tanks.
- Assessing complex issues in the case of a breakdown and repairing equipment to minimize downtime.
- Performing mechanical and electrical repairs.
- Troubleshooting equipment that doesn't perform as expected.
- Inspecting equipment for signs of wear and tear.
- Escalating equipment issues to maintenance supervisors.
- Scheduling future maintenance tasks.
- Managing inventory, like spare parts, tools, and materials, for future maintenance work.
These maintenance tasks require strong technical skills and adaptability. For maintenance managers in manufacturing facilities, organizing these activities through a maintenance management system helps prioritize critical repairs and track completion rates across teams.
Five strategies used in industrial maintenance
Industries that rely heavily on industrial maintenance include manufacturing, construction, mining, oil and gas, electricity, and automotive. Businesses within these sectors rely on hundreds of expensive, critical pieces of equipment to fulfill customer expectations.
That's why running a smart maintenance program is critical to long-term success. A solid plant maintenance plan helps optimize costs, maximize uptime, and increase long-term profitability.
Industrial maintenance is about fixing problems before they happen so critical equipment doesn't fail unexpectedly. Most industrial facilities use a combination of maintenance strategies to meet these goals, including:
Preventive maintenance
Preventive maintenance (PM) involves a proactive approach to equipment upkeep. It requires routine servicing to prevent future failures, achieving the kind of results that helped Electro Cycle increase planned maintenance by 30%.
Plant managers schedule periodic maintenance based on machine usage, time-based recommendations, and equipment history. A common example of industrial preventive maintenance is lubricating production line bearings every 1,000 operating hours or inspecting heating, ventilation, and air conditioning systems quarterly in food processing facilities.
Reactive maintenance
Reactive maintenance refers to tasks performed after equipment failure has already occurred. Generally, reactive maintenance assignments fall into two categories: run-to-failure maintenance and emergency maintenance.
Plants often allow certain assets to break down before doing maintenance on them. Managers often won't schedule preventive maintenance on noncritical, inexpensive, and easily replaceable assets. For example, run-to-failure maintenance is the ideal maintenance strategy for a light bulb.
Reliability-centered maintenance
Reliability-centered maintenance (RCM) is a proactive maintenance framework that matches each asset with the most cost-effective maintenance strategy.
RCM programs combine preventive and reactive approaches based on equipment criticality and failure patterns. This strategic approach helped Titan America decrease unplanned maintenance by 30% across their facilities.
An increasingly essential aspect of RCM is predictive maintenance (PdM). Technologies like vibration analysis, oil analysis, and thermal imaging help maintenance teams predict failures before they occur, enabling precise repair scheduling.
Condition-based maintenance
Condition-based maintenance (CBM) is another advanced maintenance framework for performing maintenance based on immediate insights from equipment data. Plant managers monitor moment-to-moment asset conditions using sensor devices designed to detect impending breakdowns.
The goal of CBM is to improve maintenance spending without sacrificing efficiency or reliability. A typical application of CBM is to monitor pressure readings on piping systems. Food and beverage manufacturers often rely on current condition diagnostics to ensure unexpected pipe bursts never disrupt production lines.
Predictive maintenance
Predictive maintenance is a data-driven approach to asset upkeep that aims to prevent failures before they occur. By using up-to-the-minute information from equipment sensors, predictive maintenance enables teams to identify potential issues early.
Common PdM techniques include vibration analysis, temperature readings, sound-level measurements, oil analysis, and infrared thermography. These techniques help maintenance managers plan repairs with precision, minimizing operational disruptions.
This method anticipates equipment failures before they occur, allowing maintenance staff to stay ahead of failures and eliminate production interruptions. This method lets teams schedule repairs only when necessary, reducing unnecessary downtime and improving asset reliability.
Industrial maintenance best practices
Effective industrial maintenance is about staying proactive, organized, and ahead of potential issues. By implementing proven strategies, like preventive and condition-based maintenance, maintenance teams can extend the life of equipment. In turn, this minimizes downtime and improves overall efficiency.
Whether you're a manager or technician, these best practices will streamline your maintenance processes and keep your facility running smoothly.
Use meters for condition monitoring
Condition monitoring involves using sensors, meters, and diagnostic tools to track machinery performance in real-time. This approach enables predictive maintenance strategies that catch problems before they cause failures.
For example, if vibration sensors on a conveyor system detect unusual fluctuations, this signals potential bearing wear or misalignment. Maintenance teams then schedule repairs during planned downtime rather than facing emergency breakdowns.
By catching these small issues early, facilities prevent costly failures that shut down entire production lines for hours or days.
Report on and analyze asset health over time
Consistent monitoring and reporting on asset health is key to improving equipment performance. By generating regular reports and analyzing historical data, teams identify trends that indicate wear and tear or declining performance.
A good example would be a machine's energy consumption gradually increasing over time. This might signal the need for an inspection or the replacement of an electrical part. This information helps maintenance teams make informed decisions and prioritize repairs that extend the life of equipment.
Analyzing asset health trends helps stay ahead of breakdowns and minimize long-term maintenance costs.
Provide documentation to ensure safety and compliance
Accurate documentation is essential for maintaining safety standards and complying with industry regulations. By keeping thorough records of maintenance activities, inspections, and repairs, teams ensure that the equipment is safe to operate and meets regulatory requirements.
For instance, documenting routine safety checks on industrial equipment helps prevent accidents by ensuring the equipment runs safely. It also provides proof of compliance during audits. Proper documentation also identifies recurring issues and avoids potential penalties for non-compliance.
Implement preventive maintenance schedules to reduce downtime
Preventive maintenance is one of the most effective ways to avoid costly equipment failures. By regularly servicing machines, maintenance teams extend the lifespan of assets and prevent unexpected downtime.
For instance, routine oil changes and filter replacements on vehicles ensure that they remain in top condition. A well-planned preventive maintenance schedule helps prioritize tasks, reduces the chance of emergency repairs, and keeps operations running without disruption.
Maintain an asset inventory management system
Keeping an accurate asset inventory helps streamline maintenance operations and prevent disruptions. An asset inventory management system allows maintenance teams to track the location, condition, and life cycle of critical equipment and parts.
For example, a manufacturing plant receives an alert when a production component is running low, letting them know to order replacements in advance. This reduces the risk of production delays due to unavailable stock.
Maintaining an up-to-date inventory helps teams improve operational efficiency by ensuring they have what they need when they need it.
Enable mobile communication between your maintenance technicians and managers
Communication tools, like those available through a maintenance management system, keep technicians and managers connected wherever they are. For example, a technician updates a work order from the field to inform the manager of a repair's status, while the manager adjusts schedules or prioritizes tasks as needed.
This approach helps minimize downtime by enabling quick responses to changes, preventing delays, and ensuring teams remain in sync.
The bottom line on industrial maintenance
Modern industrial maintenance requires more than reactive repairs. It demands a smart approach that combines preventive, predictive, and condition-based strategies. The best maintenance teams use mobile maintenance management platforms to coordinate work, monitor equipment, and give technicians instant access to data.
MaintainX bridges the gap between traditional maintenance practices and the digital tools that today's industrial workforce needs. Our platform delivers measurable results: customers report an average 32% reduction in unplanned downtime and 32% savings in monthly maintenance costs.
Ready to transform your maintenance operations? Sign Up for Free and see how MaintainX helps your team achieve operational excellence.
Industrial Maintenance FAQs
What it takes to become an industrial maintenance professional varies from industry to industry. However, most organizations hire for a broad range of skills.
Don’t worry—you don’t need to familiarize yourself with every type of industrial asset–only the critical mechanical systems most frequently relied upon. Plants don’t expect their maintenance workers to know everything about every asset.
Companies frequently outsource certain work orders to third-party contractors. Below are answers to common questions regarding how to become an industrial maintenance professional and what the work entails.
Industrial maintenance workers need a diverse skill set to excel in their roles. Candidates need a solid understanding of electrical and mechanical systems, along with hands-on experience in industrial maintenance technology. A background in mechanical engineering or a related field is also valuable. Familiarity with OSHA regulations is essential for maintaining workplace safety. Additionally, the job demands physical strength for working with heavy equipment, strong troubleshooting skills for addressing mechanical issues, and proficiency in using computers for reporting and record-keeping. Communication and time management skills are equally important to coordinate effectively with teams and ensure the timely completion of tasks.
To qualify as an industrial maintenance engineer, candidates typically need a bachelor’s degree in industrial engineering, mechanical engineering, or a related field. Practical experience in maintaining and repairing industrial equipment is also valuable. Candidates often gain this experience through internships or entry-level positions. Engineers must be skilled in analyzing equipment performance, developing maintenance strategies, and improving the operational efficiency of a variety of equipment. Familiarity with industry standards and safety regulations is also crucial. Additionally, strong problem-solving abilities, proficiency in using maintenance management software, and good communication skills are necessary for coordinating with maintenance staff and management.
Entry-level maintenance technicians typically earn competitive wages, while experienced maintenance managers in manufacturing command six-figure salaries. Location and industry specialization significantly impact compensation levels.
The four primary maintenance strategies are:
1) preventive maintenance, which involves scheduled tasks to prevent failures.
2) reactive maintenance, which addresses failures after they occur.
3) predictive maintenance, which uses data and sensors to predict failures before they happen
4) reliability-centered maintenance, a comprehensive approach that combines other strategies to optimize asset performance and cost-efficiency.
Many entry level roles require only a high school diploma plus on-the-job training, though an associate's degree in industrial technology provides better advancement opportunities. Certifications like Certified Maintenance and Reliability Professional for managers and Certified Maintenance and Reliability Technician for technicians show expertise and lead to higher-paying positions.
Success requires combining technical hands-on experience with leadership and strategic planning skills. Pursuing CMRP certification, learning project management, and gaining maintenance management system expertise are effective steps for advancement in maintenance management.
Asset-intensive industries have the highest demand for skilled maintenance professionals. These include manufacturing, food and beverage, oil and gas, logistics and distribution, and facilities management. These sectors rely heavily on equipment uptime for production and operational continuity, making industrial maintenance a critical function.
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