Reactive Maintenance: Immediate Response for Optimal Performance

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Reactive Maintenance

Reactive maintenance, sometimes called corrective maintenance, refers to equipment maintenance strategies in which maintenance is performed only after an asset has failed.

The Reactive Maintenance Approach is usually one of the most widely used maintenance strategies today, in addition to the cost of maintenance during asset outages or for necessary repairs, general pro-maintenance preventive, and predictive maintenance.

Reactive maintenance is the process of repairing an asset according to standard operating conditions after a performance degradation or malfunction has been observed. 

Benefits of Reactive Maintenance

Reactive Maintenance Meaning usually carries less initial costs and requires lower staffing requirements compared to proactive forms of care. The activities are limited to the correction of the identified problems and there is no need for unnecessary preventive actions. Reactive Maintenance makes sense for certain equipment and perhaps even some operations, but it is best described in the previous examples of light bulbs.

However, reactive maintenance for more complex machines may have risks that outweigh its benefits, as it may take longer to repair and have a significant impact on production and performance.

A typical factory may have some critical equipment on which production and performance are highly dependent. Unplanned failures can cause serious production and safety problems that are very costly to correct compared to the investment of time and resources in preventive measures.

Advantages of Reactive Maintenance

  • It requires little or no planning: 

When predicting a malfunction in advance and reacting to it instead of preparing for it, you need to be prepared on your schedule.   

  • Lower implementation costs: 

All the financial resources required to carry out the reactive maintenance strategy are used only when the asset deteriorates, so there are very few upfront costs.

  • Fewer full-time employee needs: 

Reactive maintenance is not labor-intensive, freeing up staff and resources for other business purposes until the assets break even. 

  • There are no periodic outages: 

there is no need to plan a shutdown, because it is not a periodic shutdown of production to repair assets.

Disadvantages of Reactive Maintenance 

  • Unplanned downtime: 

Failure to repair assets regularly can lead to the risk of unexpected equipment failures and costly outages. Much-needed equipment may not be usable until it has been properly repaired and returned to normal operating order.

  • Expensive Repairs: 

If an asset is critical for normal business transactions, it can be expensive to close it to protect the asset. In addition to work stoppages, there are also costs associated with hiring the necessary October technicians to come and make repairs.

  • Difficult budgeting: 

When you don’t know which assets will break, when, or how long it will take to fix, planning maintenance budgets around large-cost asset failures is a difficult task for many organizations. 

  • Delayed Sourcing: 

Without a complete maintenance plan or spare parts storage room, it can take months to supply those who need to perform critical repairs. If a critical asset is damaged, maintenance may be delayed until the necessary parts for repair are found. 

  • Unsafe working conditions: 

If assets are not intentionally checked as part of a reactive or fail-safe maintenance strategy, workers are exposed to the risk of operating unsafe equipment.

  • Poor performance: 

Assets that are not repaired regularly not only destroy everything at once, but also their quality decreases over days, months, and even years. Assets that are constantly put under stress without requiring regular maintenance are unlikely to perform at optimal levels.

  • High energy costs: 

When the performance of an asset deteriorates, the efficiency of the asset also decreases. Assets that operate for a long time without proper maintenance consume more energy, increase costs, and contribute to more carbon emissions.

Types of reactive maintenance

Reactive maintenance can be used as a general term to refer to maintenance activities performed in response. Different types of reactive maintenance may occur in different situations that require maintenance activities.

1- Emergency maintenance

It is an urgent maintenance activity that is necessary to maintain the functioning of the asset. Urgent care is a response to urgent safety requirements that need to be addressed. Such maintenance is often prioritized over normal activities, which can lead to severe downtime and a backlog of schedules.

If an asset stops working due to a fault, reactive-type fault maintenance may be required. A normal candidate for fault maintenance is equipment that does not work but is considered repairable.

2- Corrective maintenance

Although excessive interruptions in performance have not yet occurred, there are cases when some faulty components have been noticed during related or unrelated maintenance procedures. The opportunity to correct problems that arise when performing other procedures may be covered by corrective care.

Typically, unexpected or unplanned maintenance activities occur as a response to some initial cause and can be described as reactive maintenance.

3- Fault maintenance: 

This is a type of maintenance that is performed only when the equipment fails or completely fails. This is the most reactive form of maintenance, as no attempt is made to prevent the malfunction; instead, the focus is on restoring the device to normal working conditions after the malfunction.

Example of reactive maintenance

Since reactive care can be applied to a wide variety of equipment and devices, it may be useful to look at some examples that show how the average person encounters activities similar to reactive care. Here are 2 simple examples:

  • Office maintenance: 

If a business owner repairs a roof leak only after it starts, or replaces a defective furnace after it malfunctions in the middle of winter, this is another example of dealing with burst water pipes only after they cause flooding.

  • IT systems: 

In IT departments, IT is a kind of reactive maintenance to handle server or network problems only after a system outage or data loss has occurred.

  • Hospital equipment: 

Reactive care in the medical field is performed by repairing a damaged MRI device, ventilator, or other critical equipment after it malfunctions.

  • Car maintenance

Let’s assume that the car does not start because all the batteries are exhausted. It is obvious that the solution is to replace the battery, which is a kind of reactive maintenance. But as you may have experienced, there may be opportunities to catch battery problems and other vehicle problems before. If you change your oil regularly (this is a form of preventive maintenance), you may want to consider performing corrective maintenance on other auto parts that your technician may recommend to be serviced.

Fixing things as they break down is a normal reaction to situations and events. Reactive maintenance can be done for the general direction that you or your facility are taking, or it can be allowed to be identified with preventive maintenance procedures that you already have.

What’s the difference between Reactive Maintenance and Proactive Maintenance

Reactive maintenance is defined as maintenance tasks caused by equipment failures, mishaps, and malfunctions. 

Proactive maintenance refers to a preventive maintenance approach that predicts defects in advance and prevents them from occurring. Plan maintenance activities based on data collected from computerized maintenance management systems (CMMS), machine sensors, and situation-based monitoring mechanisms. Maintenance aims to address the root cause of asset failure. 

You need to get Keysmart CMMS System to run your Reactive Maintenance

It is important to implement a computerized Maintenance management system (CMMS) to effectively manage Reactive Maintenance. The benefits of using Keysmart CMMS for reactive maintenance include:

  • Streamlined work orders: 

Efficiently create, assign, and track maintenance work orders to respond to equipment failures promptly.

  • Asset tracking: 

Keep a detailed record of all assets, including maintenance history and performance data, to better manage reactive maintenance tasks.

  • Resource management: 

Allocate and monitor the use of resources, such as spare parts and technician time, to optimize maintenance work.

  • Real-time monitoring: 

Access real-time data on equipment status and maintenance activities to quickly identify and solve problems.

  • Reporting and Analytics: 

Create comprehensive reports and analyze maintenance trends to identify recurring problems and develop future maintenance strategies.

Frequently Asked Questions

What is reactive maintenance?

Put simply, reactive maintenance, also known as fault maintenance, involves dealing with equipment problems when they occur. Instead of planning maintenance tasks in advance, wait for the equipment to fail and then repair it.

What is the difference between reactive and corrective maintenance?

Corrective maintenance is a proactive approach that focuses on fixing an identified problem, while reactive maintenance is a hands-on approach until a malfunction occurs. Breakdown Maintenance is essentially reactive maintenance but refers specifically to actions performed after a fault

What is reactive property maintenance?

Reactive maintenance is performed to cope with sudden failures that occur. Such failures may be due to equipment malfunction or human error

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One thought on “Reactive Maintenance: Immediate Response for Optimal Performance

  1. Rawda says:

    This is so well-researched and thorough. I’m impressed.

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