Programmed Maintenance – Reduce Downtime, Save Costs

M.A.S.S. Electrics

What is Programmed Maintenance?

Programmed Maintenance—also known as preventative or scheduled maintenance—is a proactive approach to maintaining equipment, systems, and infrastructure. Instead of waiting for something to break down, programmed maintenance involves regularly scheduled inspections, servicing, and repairs to prevent failures before they happen.

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Why Programmed Maintenance Pays Off

In industrial operations, downtime is one of the most expensive risks. Whether it's a seized motor, a tripped circuit, or a failed component, every minute lost can mean thousands in lost productivity.

Here’s what the data shows:

Preventive maintenance can reduce equipment downtime by up to 30%
63% of maintenance costs are related to corrective maintenance
Companies that implement preventive maintenance see an average of 12% reduction in total maintenance costs
Proper preventive maintenance extends equipment lifespan by 25-30%
70% of maintenance technicians believe preventive maintenance improves safety
Implementing preventive maintenance can decrease reactive maintenance by 35%
Preventive maintenance helps in reducing machinery failures by up to 40%
56% of companies report improved equipment reliability through preventive maintenance
Scheduled preventive maintenance can increase equipment uptime by 20-50%
Preventive maintenance can lower energy consumption of machines by 10-20%
Companies practicing preventive maintenance experience 25% fewer safety incidents
80% of maintenance costs are incurred after equipment failure, emphasizing the importance of preventive strategies
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Annual Downtime Comparison

This bar chart shows how Programmed Maintenance dramatically reduces downtime compared to reactive approaches:

Reactive Maintenance: ~300 hours/year of downtime
Programmed Maintenance: ~75 hours/year
75% reduction in downtime
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Real Outcomes from Our Work

When we begin working with new clients, they’re often stuck in a cycle of breakdowns and emergency repairs. Our programmed maintenance approach flips the script:

Pest Management – What We Can Offer

Rodents and pests pose a serious threat to industrial electrical systems. Chewed cables, contaminated switchboards, and nesting in control panels can lead to electrical faults, fire hazards, and costly downtime.

We offer proactive pest management solutions tailored to industrial environments, designed to protect your infrastructure and maintain operational integrity.

What we can do:

Relocate vulnerable cabling to protected conduits and elevated pathways
Seal switchboards and enclosures to eliminate entry points for pests
Install rodent deterrents such as ultrasonic devices, bait stations, and exclusion barriers
Clean and inspect affected areas, restoring safe operating conditions

Benefits to your operation:

Prevent electrical faults caused by pest interference

Reduce fire risk from exposed or damaged wiring

Maintain compliance with safety and hygiene standards

Protect critical systems from unexpected outages

Safety System Upgrades – What We Can Offer

We offer full-scale upgrades to your site’s safety infrastructure, including the implementation of Category 4 Safety Systems—the highest level of machine safety integrity under ISO 13849-1.

What we can do:

Review your current safety systems for compliance gaps
Design and install redundant safety circuits, dual-channel relays, and fail-safe emergency stops
Integrate light curtains, interlocks, and guarding systems for high-risk machinery
Ensure full compliance with AS/NZS 4024, WorkSafe, and other relevant standards

Benefits to your operation:

Improved worker safety and reduced risk of injury

Stronger compliance posture and reduced liability exposure

Enhanced system reliability and easier fault recovery

Peace of mind knowing your site meets the highest safety standards

Motor Protection – What We Can Offer

We provide comprehensive motor protection services to ensure your equipment runs efficiently and reliably—without nuisance tripping or premature failure.

What we can do:

Conduct a full site audit of motor circuits and load profiles
Measure actual current draw and thermal performance
Adjust or replace overload protection settings to match correct full load current (FLC) ratings
Install phase failure relays, thermal sensors, and surge protection where needed

Benefits to your operation:

Eliminate unnecessary motor tripping and downtime

Prevent overheating and burnout, extending motor lifespan

Improve energy efficiency and reduce maintenance costs

Ensure motors are protected under all operating conditions

Switchboard Integrity – What We Can Offer

Industrial switchboards are critical to site operations—but they’re also vulnerable to dust ingress, moisture, and environmental wear, especially in high-traffic or heavy-duty environments.

We offer comprehensive switchboard integrity solutions to ensure your systems remain clean, safe, and reliable.

What we can do:

Install positive pressure systems to prevent dust and airborne contaminants from entering enclosures
Establish regular cleaning and inspection schedules to maintain performance and safety
Inspect for corrosion, loose connections, and insulation degradation
Repair or upgrade enclosures to meet IP ratings and site-specific requirements

Benefits to your operation:

Reduced risk of electrical faults and fire hazards

Improved system reliability and uptime

Extended lifespan of switchboard components

Compliance with safety and maintenance standards

Cable Management – What We Can Offer

Poor cable management can lead to mechanical damage, trip hazards, and electrical faults. In industrial environments, proper routing and protection of cabling is essential for both safety and performance.

We provide structured cable management solutions tailored to your site layout and operational needs.

What we can do:

Re-route and secure cabling using upgraded support structures and containment systems
Protect cables from mechanical impact, moisture, and rodent interference
Label and organise cabling for easier fault finding and future upgrades
Replace damaged or non-compliant cabling with industrial-grade alternatives

Benefits to your operation:

Prevent future faults and costly repairs

Improve safety and reduce trip hazards

Enhance system organisation and maintainability

Ensure compliance with electrical standards and site protocols

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We Don’t Just Maintain—We Prevent

Our team is trained, equipped, and committed to root cause resolution. If your current provider is just pressing reset and walking away, it’s time for a change. We:

Investigate recurring faults
Resolve the underlying issue
Implement long-term fixes
Keep your operation running with minimal disruption
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Fast, Reliable, Cost-Saving Service

Low Wait Times – We respond quickly and work efficiently
Expert Technicians – Trained in industrial diagnostics and preventative strategies
Equipped for the Job – High-grade tools and parts ready to go
Onsite Support – We’re often the only crew onsite—and we step up to help beyond electrical work
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Let’s reduce your downtime and boost your bottom line.

Get in touch to build a maintenance strategy that saves you time, money, and stress. Call 1300 466 277
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Have a project in mind? Need urgent electrical support? Our team is ready to help. Whether it’s programmed maintenance, automation, or emergency breakdowns, we’re just a call or message away.

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    M.A.S.S. Electrics

    M.A.S.S. Electrics Pty. Ltd. are a family owned and operated Industrial and Commercial Electrical Service provider, established in 1985 by John Puopolo.

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