Top 8 Maintenance Planning Mistakes That Prove Costly

Proper maintenance planning is crucial for an organization’s operational efficiency as it guarantees the optimal condition of equipment, facilities, and assets, minimizing downtime and maximizing productivity. Nonetheless, despite its significance, maintenance planning often suffers from errors that disrupt operations instead of improving them.

In other words, maintenance planning mistakes can be detrimental to the success of your business. As a business owner or plant maintenance manager, it is crucial to identify and avoid these common pitfalls. In this blog post, we will discuss the most prevalent plant maintenance mistakes and provide you with valuable insights on how to steer clear of them. By implementing effective maintenance planning strategies, you can optimize your operations, enhance productivity, and ultimately boost your bottom line.


Avoidable Errors in Maintenance Planning

1. Manual Planning Maintenance Activities

Manual planning maintenance activities can lead to errors and delays. This is because manual planning is always time consuming and fraught with tedious workflows that ultimately hamper productivity and maintenance schedules. It is therefore recommended to use computerized maintenance management systems (CMMS) for efficient and accurate planning.

2. Lack of Proper Documentation

Proper documentation is crucial for effective maintenance planning. It helps in tracking maintenance history, identifying recurring issues, and ensuring compliance. Make sure to maintain detailed records of maintenance activities and inspections.

3. Struggling to Collect Data

Struggling to collect accurate and relevant data can hinder maintenance planning. Utilize advanced data collection methods and tools to gather comprehensive information on equipment performance, failure patterns, and maintenance history. This data-driven approach will enable informed decision-making and help optimize maintenance strategies.

4. Ignoring Preventive Maintenance

Neglecting preventive maintenance can result in unexpected breakdowns and costly repairs. Implement a proactive maintenance schedule that includes regular inspections, equipment servicing, and component replacements to prevent unplanned downtime.

5. Inadequate Spare Parts Inventory Management

Having insufficient or obsolete spare parts can disrupt maintenance activities and prolong equipment downtime. Implement a robust inventory management system to ensure the availability of necessary spare parts when needed.

6. Duplicate Work Orders

Duplicate work orders can cause confusion, waste resources, and delay maintenance tasks. Implement a centralized work order management system to eliminate the risk of creating duplicate orders. This ensures that maintenance activities are organized, streamlined, and completed efficiently, saving time and reducing errors in the maintenance planning process.

7. Overlooking Staff Training and Communication

Properly trained and informed staff play a vital role in effective maintenance planning. Invest in training programs to enhance technical skills and establish effective communication channels to facilitate collaboration and information sharing among maintenance teams.

8. Failure to Leverage Technology

Failure to leverage technology can significantly impede effective plant maintenance. By implementing a mobile plant maintenance solution, you can revolutionize your maintenance processes. This advanced technology enables real-time monitoring, streamlined data management, and efficient task allocation, resulting in improved maintenance efficiency and reduced downtime. Embracing technological advancements is crucial for staying competitive in today’s industrial landscape.

Remember, avoiding these common maintenance planning mistakes can lead to improved operational efficiency, cost savings, and increased productivity.

Adopt the Right Software Solution to Enhance Your Plant Maintenance!

In the light of the above discussion, adopting the right software solution can make all the difference when it comes to optimizing your plant maintenance. As discussed above, a mobile enterprise asset management solution (EAM) when utilized in the right context and leveraged to its full potential can work wonders in your maintenance planning activity.

Propel Apps, a leading digital transformation company has developed a mobile EAM solution that seamlessly integrates with the Oracle Plant Maintenance module to quickly track work orders, schedule maintenance activities, track assets, maintain digital records and do much more, without being tied up to your traditional desktop systems. And the best part is this app works even with poor internet connectivity. This way, your maintenance personnel can accomplish tasks within the normal work shifts, optimizing maintenance activities.

To know more about our software and how it can make a huge difference in your current maintenance planning landscape, schedule a call now.


  1. What Are the 4 Phases of Planned Maintenance?

    The four phases of planned maintenance are planning, scheduling, execution, and evaluation.

  2. What Are the Basic Principles of Maintenance Planning?

    The basic principles of maintenance planning include:
    Developing a maintenance strategy based on the organization’s goals and objectives.
    Conducting regular inspections and assessments to identify maintenance needs.
    Prioritizing maintenance tasks based on criticality and impact on operations.
    Creating a comprehensive maintenance schedule to ensure timely execution of task.

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