Einstein’s Definition of Insanity: “Preventative Maintenance”….well sort of….

Einstein’s quote “The definition of insanity is doing something over and over again and expecting a different result” can describe many Preventative Maintenance programs today. Every company is under tremendous pressure to reduce costs. They are looking for a different result, a better bottom line, but they are using the same old strategies to try and deliver it.


Now the assumption here is that Preventative Maintenance is wasteful, that it costs the company more money than it should if managed differently. Truth be told, Preventative Maintenance is a 1000 times better than Reactive maintenance, where the facility spends significant time and resources fire fighting and reacting to events that hurt their productivity and puts people and the process at risk of major events. But yes Preventative Maintenance is wasteful. Utilizing resources that are not necessary is the very definition of waste.

Often, the only way a company can get out of fire fighting mode is to implement a Preventative Maintenance strategy. Life gets better, there are significantly less fires and the company can manage and plan its resources using a calendar. This is when the company has the opportunity to decide, do they start collecting data, the KPI’s that impact cost and performance to begin building the database and systems required to use Predictive Analytics to drive their process, or do they settle into the easy path of letting time drive their maintenance. Most often its the hard path that leads to riches!!

If you want a different result, you HAVE to change what you are doing. Change the bottom line? Eliminate waste and wasteful activities. The only way to sustainably eliminate waste is to first identify it and then systematically use Predictive Analytics to remove it.

Quoting another great man: “The most dangerous kind of waste is the waste we do not recognize.” – Shigeo Shingo. Companies that are using Preventative Maintenance to manage their fluids are not recognizing this very significant source of waste.

At Zimmark, we set up and maintain the Predictive Analytics necessary to eliminate waste and wasteful activity associated with fluid usage in a parts manufacturing environment. Our Hidden Cost Audit is the process we use to shine the light on waste and help manufacturers sustainably improve their bottom line. Follow the link below if you want to learn more.

I want to learn about your Hidden Cost Audit.

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