Plant maintenance: what it is, how often to plan it and with which software

Plant maintenance: definition and importance

Plant maintenance includes all activities necessary to ensure the correct functioning, safety and durability of machinery, technical systems and infrastructure. Effective maintenance management reduces the risk of sudden breakdowns, optimizes operating costs and ensures compliance with current regulations. Planning maintenance is fundamental to avoid production stops, prolong the life of plants and improve company productivity.

Types of maintenance: corrective, preventive and predictive

Plant maintenance strategies are divided into three main categories:

• Corrective maintenance: intervention performed only after a breakdown. It is the fastest solution but involves risks of plant downtime and unforeseen costs.
• Preventive maintenance: activities scheduled at regular intervals to prevent breakdowns. Reduces interruption risks and prolongs asset life.
• Predictive maintenance: uses sensors, data and analysis to predict when a component is likely to fail, allowing targeted and timely interventions.

Choosing the most suitable type depends on the criticality, value and use of the plants.

How often to plan maintenance: criteria and frequency

The frequency of maintenance depends on several factors:

• Manufacturer's indications: each plant has specific recommendations on periodic checks.
• Sector regulations: for thermal, electrical or hydraulic systems, the law imposes precise deadlines (e.g., energy efficiency check every 1-2 years).
• Operating conditions: harsh environments or intensive use require more frequent interventions.
• Breakdown history: analyzing data helps optimize planning.

An effective maintenance plan takes all these elements into account to ensure safety and continuity.

How to organize an effective maintenance plan

To structure a truly functional maintenance plan, follow these steps:

• Asset census: list all plants and equipment to be managed.
• Risk analysis: evaluate the criticality and impact of any failures.
• Definition of priorities: establish which plants require more attention.
• Planning interventions: schedule activities based on deadlines and available resources.
• Monitoring and review: periodically update the plan based on the results and data collected.

Maintenance management software: what they are and advantages

Plant maintenance software (CMMS – Computerized Maintenance Management System) are digital tools that allow you to automate, track and optimize all maintenance activities. The main advantages include:

• Automatic planning of interventions and deadlines.
• Centralized management of assets, documentation and maintenance history.
• Real-time monitoring of plant status and activities.
• Advanced reporting to analyze costs, times and performance.
• Integration with IoT and digital twins for predictive maintenance.
• Mobile access for technicians and managers even when off-site.

The adoption of a CMMS allows for reduced errors, optimized resources and improved collaboration between teams.

How to choose the right software for plant maintenance

To identify the maintenance software most suited to your needs, carefully evaluate:

• Ease of use and speed of implementation.
• Specific features for your sector and type of plants.
• Integration with other company systems (ERP, IoT, BIM).
• Scalability and possibility of customization.
• Technical support and training for staff.

Choosing the right solution means optimizing time, costs and maintenance quality.

Main software for plant maintenance

Several CMMS software are available on the market that respond to different needs. Among the most widespread and appreciated are:

• CARL Software: complete management of preventive, corrective and predictive maintenance.
• Mainsim: Italian platform with ticketing functions, asset management and mobile app.
• Hopperix: scheduled planning, automatic notifications and document traceability.
• Blulink – Quarta EVO: maintenance module integrated with cost and KPI monitoring.
• Fluentis ERP: maintenance management integrated in an ERP environment.
• Italsoft: collaborative web solution accessible from mobile.
• Machina Web: dashboard, ticketing, warehouse and mobile modules.

The choice depends on company size, complexity of the plants and digitalization objectives.

Key points to remember about plant maintenance

• Planning maintenance is essential for safety, efficiency and savings.
• CMMS software simplifies management and improves control.
• Data analysis and digital technologies allow for increasingly predictive and intelligent maintenance.