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Preventative Maintenance Systems
Proactive Solutions for Minimising Downtime and Maximising Equipment Life
At KAMAPS, we specialise in the design, implementation and integration of advanced preventative maintenance systems for manufacturing and process industries across the United Kingdom. Our solutions enable businesses to anticipate mechanical failures, reduce unplanned downtime, and lower maintenance costs by leveraging real-time data from equipment, sensors, and connected platforms.
We support a wide range of industrial environments, from small workshops to complex multi-line factories, with scalable solutions that integrate seamlessly with both legacy machinery and modern Industrial Internet of Things (IIoT) platforms.
What Is a Preventative Maintenance System?
Planned preventative maintenance (PM – PPM) is a proactive maintenance strategy that involves routine inspection, monitoring, and servicing of equipment to prevent unexpected breakdowns or process interruptions. Unlike reactive maintenance—which waits for failure—preventative maintenance is based on time, usage, or condition-based indicators.
Modern preventative maintenance systems utilise data acquisition, sensor technology, cloud computing, and maintenance scheduling tools to automate the process and deliver actionable insights.
Our Preventative Maintenance Services Include:
- Site survey and asset evaluation
- Selection and installation of condition monitoring sensors
- Vibration analysis, temperature monitoring, oil analysis, and motor diagnostics
- Integration with existing PLC/SCADA systems and MES/CMMS platforms
- Cloud-based dashboards and mobile access for real-time monitoring
- Automated maintenance scheduling based on usage or condition thresholds
- Historical trend analysis and reporting tools
- Alerts and notifications for predictive interventions
- Support for legacy equipment integration and IIoT retrofitting
Equipment Requiring Preventative Maintenance
We specialise in monitoring and maintaining critical industrial equipment such as:
Electric motors and gearboxes
Pumps, fans, and compressors
Heat exchangers and boilers
Conveyors, bearings, and actuators
Injection moulding machines
CNC machinery and robotic arms
HVAC systems
Control panels and power distribution boards
Failure of these assets can result in significant costs due to downtime, repair parts, labour, lost production, and quality rework.
High Cost of Failure Without PM Systems
Without an effective preventative maintenance strategy, companies face risks such as:
Unplanned downtime costing £10,000–£50,000+ per hour depending on the process
Catastrophic equipment failure requiring total replacement
Product losses from quality deviation or contamination
Regulatory penalties from non-compliance or safety incidents
Energy inefficiency due to worn or degraded equipment
Extended lead times on emergency part sourcing and service
Preventative maintenance significantly reduces these risks, offering measurable ROI through cost avoidance and operational resilience.
Legacy System Integration & IIoT Retrofitting
Many manufacturers operate legacy machinery without native connectivity. We offer retrofit solutions that enable older equipment to be monitored and maintained using modern tools, without the need for full replacement.
Services include:
Installation of wireless vibration and temperature sensors
Use of edge devices to collect data and transmit to cloud platforms
Integration with CMMS (Computerised Maintenance Management Systems)
Dashboards accessible via web and mobile interfaces
Scalable cloud platforms with secure data storage and analytics
This allows businesses to modernise maintenance operations while preserving capital investment in legacy assets.
Common Applications of Turnkey Projects & Custom Solutions
Motor & Drive Condition Monitoring
Description: Real-time monitoring of vibration, current draw, and bearing temperature for motors and VFDs.
Benefits:
Early detection of wear or misalignment
Prevention of unplanned stoppage in production lines
Extended motor lifespan and reduced repair frequency
Pump and Compressor Health Monitoring
Description: Monitoring flow rate, pressure, and power consumption to detect cavitation, leaks, or mechanical fatigue.
Benefits:
Lower energy consumption through performance optimisation
Reduced downtime from mechanical failure
Enhanced efficiency in critical fluid handling operations
Predictive Maintenance for Legacy Machinery
Description: Retrofits with wireless sensors and data logging units to bring older machines into the digital maintenance ecosystem.
Benefits:
Cost-effective modernisation without equipment replacement
Centralised data visibility across old and new assets
Improved reliability and planning through predictive analytics
Why Choose KAMAPS?
- UK-wide experience implementing preventative maintenance systems
- Support for both discrete manufacturing and continuous process industries
- Integration expertise with SCADA, MES, ERP, and CMMS platforms
- Customisable dashboards and reports for all user levels
- Deep knowledge of sensor technology, data acquisition, and remote access
- Ongoing service contracts for recalibration, diagnostics, and support
Data-Driven Maintenance for a More Reliable Future
With our preventative maintenance solutions, you can shift from reacting to failures to predicting and preventing them. We help build smart, connected maintenance strategies that protect uptime, extend equipment life, and lower total cost of ownership.
Get Started Today
Speak to our engineering team about designing a preventative maintenance system tailored to your operations. Book a site visit or request a demo of our cloud-based platform.