Have you ever asked yourself, “Why do I keep experiencing breakdowns?” A robust Preventative Maintenance Program is the backbone of a reliable heavy-diesel fleet. It should minimize downtime, extend asset life, and keep operations moving. But… if your preventative maintenance program isn’t delivering the results you expect, it’s time to reevaluate. Here are five telltale signs that your Preventative Maintenance Program needs a tune-up, and simple steps to fix it.
1) Increased Breakdown Frequency
What you’ll notice: more breakdowns and repairs happening even though you follow a schedule.
Why it matters: a preventative maintenance program should prevent surprises, not create them!
Simple fixes:
– Reassess preventative maintenance program intervals against OEM specs and real-world usage. Consider adjusting intervals for severe duty or high-km vehicles.
– Ensure critical systems (engine, cooling, transmission, hydraulics, and emissions) receive the right attention at the right times.
– Move toward condition-based maintenance where data shows it’s beneficial (e.g., oil analysis, temperature monitoring).
2) Rising Repair Costs
What you’ll notice: repair bills climbing month after month.
Why it matters: rising costs usually mean issues aren’t being caught early or root causes aren’t addressed.
Simple fixes:
– Track repair costs by vehicle and by subsystem to spot hotspots.
– Prioritise fixes that deliver the biggest cost savings and uptime gains.
– Perform root-cause analysis to eliminate recurring problems rather than treating symptoms.
3) Delayed Repairs
What you’ll notice: repairs or scheduled maintenance slipping past due dates.
Why it matters: delays extend downtime and disrupt productivity.
Simple fixes:
– Establish clear service schedules with simple escalation rules.
– Improve parts availability and shop capacity planning to prevent backlogs.
– Use a shared, visible maintenance calendar so everyone knows what’s due and when.
4) Poor Communication
What you’ll notice: confusion about service schedules, overdue tasks, or unreported issues.
Why it matters: effective maintenance relies on timely, accurate information.
Simple fixes:
– Standardise maintenance reporting and issue tracking.
– Set up regular status updates and briefings on current work and bottlenecks.
– Leverage digital dashboards so technicians, fleet managers, and operators stay aligned.
5) Lack of Data Tracking
What you’ll notice: few actionable KPIs or no data guiding decisions.
Why it matters: data reveals trends, predicts failures, and guides PM improvements.
Simple fixes:
– Monitor key metrics such as MTBF (mean time between failures), MTTR (mean time to repair), downtime, and preventative maintenance program compliance rates.
– Implement simple fleet maintenance software or standardised spreadsheets to collect and visualise data.
– Use the data to continuously optimize preventative maintenance program intervals and maintenance workflows.
If you recognise any of these signs, it’s time to take action and strengthen your Preventative Maintenance Program. Start by revisiting PM intervals and align them with OEM guidance and real-world usage. Consider moving to condition-based maintenance for components that wear quickly or run hot, and don’t be afraid to tighten checks on high-cost systems like the engine, cooling, and hydraulics. Improve parts availability and shop capacity to prevent delays, and establish clear, transparent scheduling so everyone knows what’s due and when.
Most importantly, base decisions on data. Track key metrics such as MTBF, MTTR, downtime, and preventative maintenance program compliance to spot trends, predict failures, and continuously optimise your maintenance plan. A stronger Preventative Maintenance Program leads to fewer breakdowns, lower repair costs, and improved fleet uptime, keeping your operations efficient and on schedule.
Ready to improve your preventative maintenance program? Follow this link to book in an audit, we’ll check over your current Preventative Maintenance Program, tailor a plan for your on road trucks, earth moving gear, and machinery, implementing a data-driven maintenance preventative maintenance program.
Explore our services: Onsite servicing, involving mechanical, auto-electrical, hydraulic and electrical repairs on all heavy diesel machinery, such as earthmoving and on-road equipment across the agricultural, mining and construction industries. Working with predictive maintenance analytics, and preventative maintenance program optimisation.
