The End of the Preventive Maintenance Checklist: Powered by AR

Keyur Bhalavat
Keyur Bhalavat Author By

Generally, maintenance refers to situations wherein a machine or part wears down or breaks, it is removed from production until it is fixed. The traditional practice consisted of regularly scheduled maintenance and reactive maintenance as needed. Preventive maintenance Checklist is more about preventing a problem that may happen in the future. Maintenance is an ongoing process that takes place in many different phases. 

Maintenance engineers spend considerable amount of time inspecting, repairing, and monitoring assets to ensure they are safe and operational. The process is time-consuming and tedious. However, with technological advancement and the advent of IIoT and AR, this is changing. 

With AR, maintenance engineers can use their smartphone to scan a machine and get a report on its current state, which includes detailed information like operation times, last service date, probable sites of failure, etc. This historical data could help an engineer predict when can the machine break down next or it would require maintenance.  

Maintenance engineers no longer need to track data and machines manually, instead can use AR and IIoT for assistance. This is not only improving the efficiency of the engineers, but also reducing the risk of machine breakdown and downtime. 

Preventive maintenance through IIoT, combined with machine learning and big data, and Augmented Reality, can save companies both time and money. 

At a manufacturing facility, preventive maintenance resulted in an astounding 545% return on investment. 

manufacturing facility

What Is A Preventive Maintenance Checklist? 

A preventive maintenance checklist is a list of tasks for inspecting and servicing manufacturing equipment for completing preventive maintenance. Preventive maintenance programs are meticulously defined, with well-documented activities for each piece of equipment. It is also regularly reviewed and adjusted as required. The checklist comprises all the necessary steps for a periodic inspection and servicing of machines, equipment, and tools. 

In a manufacturing facility, the list will have detailed instructions for each task to be done, such as making adjustments to the equipment, testing materials, or performing specific tests. It also includes a schedule for when these tasks should be completed so that they are done at regular intervals. 

A preventive maintenance checklist is a necessary for industries to reap the benefits of accomplished preventive maintenance.  

Why Preventive Maintenance Checklist Can Be Inefficient? 

Preventive maintenance checklists are designed to help technicians perform routine inspections and repairs that are needed to keep the machine from breaking down. These checklists are usually created by experts and then distributed to technicians who need them. The problem with this system is that it is not created for individual machines. This means the checklist may not be the most effective for problems that occur on different machines. Thus, it is not the most advanced solution for ensuring machine uptime and efficiency.  

The two main inefficiencies a preventive maintenance checklist suffers from are the rule of thumb schedules and human errors. 

Rule Of Thumb Schedules 

The rule of thumb schedule is a simple and easy-to-use method for estimating the frequency of maintenance. It is most commonly used in the manufacturing industry. This schedule estimates how often equipment should be serviced based on its age, type of use, and operating environment.  

These recommendations are mostly based on normal or recommended usage. They are inefficient when machines are over-used or under-used. Sometimes it costs manufacturers unnecessary bucks to replace parts that would still last for more than a year. In the manufacturing industry, this cost could be significantly high when multiplied by the number of machines in the production line. 

Human error 

The human errors in the preventive maintenance checklist in the manufacturing industry are a major problem. The checklist is usually a long document comprising technical terms and instructions. It is not easy to remember such a checklist and takes time to check each item on the list. More importantly, there are some items that are not included in this list, but they should be done regularly to maintain the equipment. The main reason behind these errors is the complexity of the maintenance schedule mentioned in the checklists.  

Every component needs a different form of maintenance, and they’re scheduled at specific times. But sometimes, maintenance dates are missed, and mistakes are made during inspection and services, which leads to machine downtime in some cases and costs companies a lot of money.  

Smart maintenance 

Industry 4.0 brings new ways for manufacturing industries to make their maintenance smarter and more efficient. Industrial internet of things (IIoT) and Augmented reality are the driving technologies of industrial 4.0 which enhance preventive maintenance. 

IIoT predictive maintenance

Embedding machinery with electronics, software, sensors, and network connectivity to collect and exchange data has many benefits in preventing maintenance in the manufacturing industry. 

IIoT provides a real-time view of equipment or process performance and can be used for predictive maintenance. IIoT improves preventive maintenance efficiency by collecting and analyzing data from equipment and sensors. The data is then used to predict when specific equipment will fail. This allows the organization to schedule maintenance before the failure occurs, which saves time, money, and resources. This can also reduce the costs associated with downtime by providing the right information at the right time. 

IIoT also helps improve efficiency in the industry by reducing the time it takes to find and fix equipment failures. The technology also reduces waste through predictive analytics, which provides insights into when equipment will need maintenance. 

Role of AR 

The idea behind augmented reality is to provide real-time information to people when they need it most. This information can be anything from a safety warning to an instruction manual or a tutorial on how to use a machine or device. For example, if a machine needs maintenance, then the worker might get instructions on what tools are needed and how to go about fixing it. 

With AR, technicians can view step-by-step visual guides for maintenance which results in reduced human errors and improved efficiency. Technicians can learn how to do tasks without any prior experience or training. They can also get help from experts by connecting remotely with them. Technicians can also record the inspection, which can be used for verification of task completion. 

AR solutions like Plutomen Workflow help on-field workers with checklists and SOPs consisting visual instructions for completing inspection process without errors. The technicians can use AR solutions to capture inspection recordings and share them on multiple platforms through an easy-to-use app. Using Plutomen Connect, technicians can connect with experts remotely and get remote assistance for complex maintenance, which saves time and money.  

GE Aviation observed an average of 8 percent to 12 percent in mechanic efficiency in maintenance while using smart glasses. 

With augmented reality, you can create a digitized checklist for maintenance and overlay the instructions in the real world. This way, workers would not need to rely on paper checklists anymore, they can resort to a more efficient workflow, and perform tasks without human errors. 


  • Faster preventive maintenance 
  • Consistent performance, regardless of who does it 
  • Less reliance on the experience of individual technicians 
  • Fewer errors  
  • No need for experts to travel to a location, saving time and travel costs 

Benefits Smart Maintenance AR

Smart Maintenance & The End Of Maintenance Checklist Powered by AR 

Smart maintenance is a new way of looking at the maintenance of machinery and equipment. The use of augmented reality and the Internet of Things (IIoT) technology helps to monitor machines remotely, giving you a better understanding of their condition, and complete the processes quicker and error-free. A maintenance checklist is a thing of the past as this new technology can be used to track any issues that arise with the machine or equipment before they become problems. The use of AR and IIoT can dramatically improve uptime and overall efficiency while reducing the burden on humans. 

Plutomen is an Augmented Reality based SaaS platform that provides AR solutions to industrial enterprises. Our products provide work assistance to the technicians for accessing digital work instructions, streamlining their knowledge for reduced errors. Book a demo of our product to know how it can be deployed at your enterprise for smarter maintenance! 

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