November 04, 2024

What Is Reactive Maintenance?

Maintenance departments face several options when it comes to how they operate. Many factors go into how they service assets, store inventory, and accomplish aspects of maintenance management. Size, resources, etc. This article focuses on the question of what is reactive maintenance.

Repairing or replacing assets only when they fail comprises the mindset known as reactive maintenance. You react when something happens rather than take steps to prevent the incident. While this method might seem cost-effective in the short term, it comes with its own set of advantages and disadvantages.

In recent years, facilities have been transitioning towards preventive maintenance, aided by Computerized Maintenance Management Systems (CMMS). This article explores ten advantages and disadvantages of reactive maintenance. Then read how adopting a CMMS can facilitate the shift towards a more proactive approach.

Advantages of Reactive Maintenance

Surprisingly, you can make an argument in favor of reactive maintenance. Today, many companies still rely on this practice. Here are ten advantages to adopting this approach.

   
1. Cost Savings in the Short Term - You only incur expenses when equipment breaks down, avoiding unnecessary preventive maintenance costs. In the initial stages, this seems efficient and effective. However, later, you’ll see why this fails.
2. Simplicity - The practice means straightforward and minimal planning and scheduling. This simplicity works for smaller facilities with limited resources.
3. Reduced Downtime for Non-critical Equipment - For less critical equipment, waiting until a failure occurs may not significantly impact overall operations. You tolerate downtime better.
4. Flexibility - You allocate resources based on immediate needs rather than predetermined schedules. This allows for a flexible approach to managing assets.
5. Preservation of Resources - Since you’re not conducting preventive maintenance (PM), you save resources. Supervisors may find some PMs unnecessary since the equipment doesn’t fail after a set period.
6. No Over-maintenance - One disadvantage of PM happens when equipment receives too much attention. Again, this relates to costs. With reactive maintenance, you don’t have that issue.
7. Focus on Urgent Issues - Since you’re saving resources, you focus on the important issues. You handle the emergency and critical better.
8. Limited Skill Requirements - Reactive maintenance may require less specialized skills. Technicians only need to address immediate failures rather than implementing planned maintenance tasks.
9. Extended Equipment Lifespan - Surprisingly, some equipment might endure an extended lifespan with this approach. The asset may last a long time, again saving maintenance costs.
10. 1Utilization of Spare Parts - You save money on purchases since you don’t use parts until failures occur.

Disadvantages of Reactive Maintenance

Many companies see the benefits of the above list. However, read further to understand that most of the time, the disadvantages hold a little more weight.

   
1. Unplanned Downtime - The most significant drawback of reactive maintenance. This leads to production losses and potential damage to other equipment. You also risk safety hazards.
2. Increased Repair Costs - PMs may look more expensive because of the constant resource usage. In the long run, major repairs run into major expenses. Lack of parts means emergency shipments. Lack of labor means overtime. Unplanned downtime means loss of production.
3. Reduced Equipment Reliability - Operating equipment until failure compromises its reliability. You risk more frequent breakdowns and disruptions to operations.
4. Safety Concerns - Reactive maintenance looks good until you face emergency safety hazards. Leaks. Exposed wiring. Damaged protective measures.
5. Difficulty in Planning - The unpredictability of breakdowns means you have a planning challenge. You might experience a labor and/or parts shortage. Read on for more on this.
6. Inefficient Resource Allocation - Emergencies mean instant attention. You risk efficiency if you don’t have available labor and parts. As mentioned before, this means emergency purchases. It all affects costs.
7. Morale Issues - Because of interruptions and safety issues, morale between employees may run low. Tension occurs when maintenance calls increase for continued downtime.
8. Environmental Impact - The increased likelihood of equipment failures leads to higher energy consumption and increased emissions. Leaks of hazardous material risk damaging soil and water.
9. Limited Asset Tracking - You don't have adequate asset management. Since you’re not tracking asset operations, you can’t predict when failures might occur.
10. Equipment Lifespan - Above we discussed some equipment that lasted longer due to the run-to-fail concept. However, you’ll find that the reactive mindset shortens the operations of most equipment. Parts wear out and assets fail with neglect.

Transitioning to Preventive Maintenance with CMMS

A Computerized Maintenance Management System (CMMS) shifts facilities from reactive to a preventive strategy.

1. Asset Tracking and Management - CMMS provides a centralized system for equipment readings and maintenance history. You’ll have a list of repairs done. You generate reports on any input information regarding each asset.
2. Scheduled Maintenance Tasks - CMMS organizes so much. This includes the scheduling of PMs. You’ll use historical data and manufacturer’s recommendations. Other schedules exist because of regulatory compliance.
3. Work Order Management - With a CMMS you’ll process work requests and generate work orders easier. A quality system offers plenty of information for priority, location, and related inventory. You can attach documents and assign skilled technicians.
4. Better Communications - You’ll use the system to coordinate with production personnel for timely repairs and PMs. You’ll receive feedback from technicians on completed work. If you use the software for purchasing, you’ll have better interaction with vendors.
5. Resource Optimization - With access to labor, you’ll reduce overtime. You view the schedules to see who’s available and to achieve better attainment with each employee.
6. Improved Safety and Compliance - PMs through CMMS software make accessing reports easier to show regulators. You reduce safety hazards with routine maintenance work.
7. Cost Reduction - In time and after proper use of the CMMS, the organization and efficiency pays off. Fewer unplanned downtime. Overall expenses reduced. You don’t replace costly equipment as often. You’ll see fewer emergency purchases.
8. Enhanced Reporting - A CMMS provides robust reporting and analytics tools. Reports on any input information. Key performance indicator (KPI) reports that help future operations.
9. Increased Equipment Reliability - With preventive maintenance, you keep equipment at a baseline functionality longer.
10. Streamlined Spare Parts Management - With the help of a quality system, you organize parts in the stockroom. You’ll note critical spares. Easily access quantities and auto-create purchase orders when low.

Conclusion

What is reactive maintenance? Going to the doctor only when you’re sick instead of regular checkups. Going to the dentist only when the tooth hurts instead of regular visits. Costly auto repairs instead of routine oil changes and tire rotation.

By using these simple home life examples, you can see how this mindset transfers to the workplace. If you have this mindset, consider using a CMMS to get you on the preventive path. You’ll find your operations run smoother and the bottom line stays out of the red.

Call Mapcon Technologies at 800-922-4336 for a world-class CMMS. Offering U.S.-based support and programming, Mapcon shows you the better path to maintenance management success.