<img height="1" width="1" style="display:none;" alt="" src="https://dc.ads.linkedin.com/collect/?pid=22923&amp;fmt=gif">

Advantages and Disadvantages of Reactive Maintenance

What is reactive maintenance?

Reactive maintenance also often referred to breakdown maintenance means that equipment repairs are done after the equipment failure.

While reactive maintenance might make sense from the first sight (repairing only when failures occur) it shouldn’t be your main strategy.

Advantages of reactive maintenance

In theory, it is much less time consuming and less costly to not maintain unbroken equipment rather then spending money, using spare parts and labor on a machine that is still running. There is no initial cost associated with reactive maintenance, and it does not require maintenance planning which involves time and labor resources. However, reactive maintenance is a very shortsighted approach. Relying only on reactive maintenance in your factory or plant is not sustainable for the long term and will have negative results.

01-reactive-maintenance

Disadvantages of reactive maintenance

Expensive

In a long term, unexpected downtime in the middle of the production can lead to damaged goods, late deliveries, losing a customer, consequently impact revenue. Additionally, relying on reactive maintenance means that labor and spare parts might not be forecasted accurately and organization won't be able to repair machinery after failure occurs. Company can end up losing money for emergency spare parts shipping and overtime.

Asset life expectancy

Reactive maintenance strategy does not involve keeping equipment running in an optimal way and therefore it does not maximize initial investment in the machinery. Maintaining your machinery before failures can increase asset life expectancy.

Safety

When maintenance work order is scheduled, workers have time to prepare and review standard procedures for maintaining specific piece of equipment. Every asset has safety requirements to complete the job correctly. With reactive maintenance everything must be more urgent and workers are under pressure. Therefore they are tend to take more risks in order to fast get machine up and running.

Time management

When you plan your maintenance activities you have time to analyze, consider and take actions based on previous data and production schedule. With reactive approach, failures occur unexpectedly, workers run around looking for the correct safety manuals and documentations as well as spare parts and tools.

Energy costs

When asset is not properly maintained, it uses more energy. Simple maintenance jobs like greasing parts or changing filter can reduce energy consumption by 15%.

 

Asset Management Analytics

 

Interested in saving money on Maintenance Costs?

You can access more useful resources and research papers here.

 

Articles

Work Order Management: The Right Way
  Work order management. Wow. It doesn’t sound exciting, does it? But hang in there for a...
Beginners Guide : Industrial Lubrication
Lubrication. That word makes some people smile. But in industrial organizations world-wide, it...
Reliability & Availability: How to Get There with FMEAs and P-F Curves
For organizations that suffer from unexpected failures and unplanned downtime, Failure Modes and...
The Top 5 Benefits of Condition-Based Maintenance in the Age of The IIoT
  The benefits of condition-based maintenance (CBM) are now as clear as they ever were.  
Vibration & IIoT Sensors
  Vibration analysis is a key technology in the ever-changing world of IIoT and predictive...
5 Reasons IoT Projects Fail and How to Avoid It
  Many Industrial IoT projects fail. Many IIoT value chains have ended up with broken, rusting...
FREE EAM/CMMS for Microsoft Business Central
  Do you know how often your assets need maintenance? Is your inventory management effective? Do...
IoT Sensors in Maintenance
  Maintenance is changing. Rapidly. Predictive maintenance is evolving almost by the hour. Just...