Maintenance of equipment is a fundamental aspect of facilities management. The extent and complexity of this task, as well as the amount of equipment downtime it may cause, depends entirely on the maintenance plan implemented by your organization. While reactive maintenance is a commonly used strategy in various industrial sectors, it may not be the most suitable choice for your facility. In fact, it could prove to be detrimental in the long run. It is crucial to fully comprehend the reactive maintenance cycle and consider alternative methods instead of assuming it is the only appropriate maintenance approach for your requirements.

What is Reactive Maintenance?

Reactive maintenance, commonly known as breakdown maintenance, involves the practice of only addressing equipment issues once they have already failed. This approach stands in contrast to preventive maintenance, which emphasizes the ongoing inspection and servicing of assets to prevent breakdowns. Corrective maintenance, on the other hand, focuses on repairing equipment only when it is not functioning properly. This could mean addressing issues that affect performance but do not cause a complete stoppage, or those that jeopardize safety or the integrity of connected machinery.

It is important to consider that not dedicating time and resources to maintaining perfectly operational equipment can be a more efficient approach. This includes using spare parts and labor on machines that are still functioning well. When incorporated as part of an overall maintenance plan, reactive repairs can be justified. It is crucial to assess the specific situation and prioritize accordingly. If the equipment is not a top priority and the emergency repair is quick and cost-effective, a reactive approach may be just as effective as a proactive one.

Regrettably, organizations that prioritize other areas or face budget constraints may defer overall maintenance, opting to only address emergency repairs as needed. While reactive maintenance may seem logical in theory – repairing equipment only when it fails – relying solely on this approach is not recommended as a primary maintenance strategy.

Challenges with Reactive Maintenance

Engaging in reactionary or reactive maintenance is ultimately a short-sighted strategy for factories and plants. This method is not sustainable in the long term and is likely to result in negative consequences over time. The exact issues that may arise can differ across industries and facilities, but typically, there are several common problems that can be linked to the use of reactive maintenance techniques.

High Cost

The irony of a reactive maintenance program is that its initial goal of saving costs can ultimately lead to a costly problem of unexpected downtime. By adopting a reactive approach, indicators of machine issues that could result in asset failure are often ignored, causing disruptions and inefficiencies in essential facility operations. This can ultimately lead to production delays, damaged products, late shipments, and ultimately, dissatisfied customers. Negatively affecting revenue, especially client displeasure, may lead to more than just sales loss. It can create a negative reputation and decrease customer base, impacting your bottom line. Additionally, reactive maintenance can cause inaccurate budget forecasting for labor and parts, affecting the affordability of repairs made at the last minute when assets fail.

Finally, it is important to note that poorly maintained equipment consumes more energy compared to regularly serviced equipment as part of a preventative maintenance strategy. This is due to the equipment having to exert more effort to operate efficiently, resulting in increased power consumption and unnecessary expenses.

Lowered Asset Life Expectancy

Failure to regularly maintain equipment can result in increased risk of failure and decreased longevity, ultimately leading to a higher cost in replacing assets prematurely. By neglecting routine maintenance, companies may not be maximizing their initial investment in machinery or other assets, potentially resulting in frequent repairs and increased expenses. It is important to prioritize regular maintenance to ensure optimal performance and prolong the lifespan of equipment.

Diminished Safety

In a proactive maintenance approach, work orders for asset repairs or checkups are scheduled at regular intervals or based on ongoing condition monitoring. This allows workers to adequately prepare for the task and ensure they are familiar with the standard procedures for maintaining specific machines. It is crucial to adhere to safety requirements for each asset to complete the job correctly. On the other hand, with a reactive maintenance strategy for unforeseen repairs, the sense of urgency is heightened, putting workers under pressure. This can lead to increased risks being taken to expedite the job, compromising safety and fairness to employees. Feeling constantly pressured or unheard can cause workers to disengage and perform less effectively.

Time Management

Unexpected failures can occur when relying on reactive maintenance for repairs. In these situations, workers may frantically search for safety documentation, spare parts, and tools, leading to delays in completing maintenance tasks efficiently. Despite time constraints and pressure, tasks may not be completed promptly.

Accelerate Equipment Maintenance with Nirmalya EAM

Transform your asset management strategies with Nirmalya's cutting-edge Enterprise Asset Management platform. Featuring an intuitive interface and robust functionalities, our software simplifies the management of your enterprise assets. Maximize asset utilization, reduce downtime, and boost operational efficiency with features like preventive maintenance scheduling, real-time asset tracking, and work order management. Leverage advanced reporting and analytics capabilities to gain valuable insights into asset performance and make informed decisions. Enterprise Asset Management is crucial for organizations to effectively monitor, evaluate, manage, and improve the quality and reliability of their assets. By implementing optimal methodologies, EAM empowers maintenance teams to gain better control over complex operational environments.

If you are seeking to explore the powerful capabilities of Nirmalya EAM and enhance your maintenance operations with a more streamlined framework, we encourage you to contact us promptly.