Company can end up losing money for emergency spare parts shipping and overtime. Every asset has safety requirements to complete the job correctly. Being reactive sometimes has a negative connotation but, in fact, it is as much a part of running a business as being proactive is. Reactive maintenance does not keep the systems running in optimal âas newâ condition. Â Or the slight misalignment of a shaft not only damages the bearing but over time can result in a cracked or seized gearbox or even damage to the shaft itself. Many providers, especially in the EAM space avoid this question. The first consideration is to group your assets based on their criticality and ensure that High Critical Assets are maintained more proactively while low/non-production assets can be maintained more reactively. Over time, systems that have been maintained reactively, deteriorate faster due to related induced failures and therefore do not maximize their initial capital cost investment. Reactive maintenance also often referred to breakdown maintenance means that equipment repairs are done after the equipment failure. A second consideration might be to split the maintenance teams into preventive and reactive crews to handle the different work types. Relying only on reactive maintenance in your factory or plant is not sustainable for the long term and will have negative results. However, reactive maintenance is a very shortsighted approach. Planned work may be pushed or canceled completely resulting in future unexpected failures that will result in additional unplanned work and future preventive work being missed. When asset is not properly maintained, it uses more energy. 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. If not repaired correctly soon after (and typically this rarely happen), the issue could reoccur and cause more downtime. Simple maintenance jobs like greasing parts or changing filter can reduce energy consumption by 15%. As a result, there is less confusion around who is doing what and when. Emergency repairs are usually prioritized at the expense of planned preventive work. 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. When maintenance work order is scheduled, workers have time to prepare and review standard procedures for maintaining specific piece of equipment. Also, there is the uncertainty around the length of delay due to the unplanned repair. Reactive maintenance strategy does not involve keeping equipment running in an optimal way and therefore it does not maximize initial investment in the machinery. Advantages and Disadvantages of Reactive Maintenance, Asset Management Partner Presales Support. should outperform those of reactive agents (LaPorte and Consolini, 1991; Pauchant et ai, 1990). Reactive maintenance does the bare minimum to get the system up and running again, due to the pressure to return the plant back to production. Â In essence, companies pay for their resources (technicians, special tools, equipment, etc.) Repairing damaged equipment quickly is important for minimizing downtime. Continued increases in planned maintenance eventually reach the point where it becomes too costly. In the case of failure, parts may need to be rush ordered or, even worse, you must have spare assemblies and or sub-assets in your warehouse; but moreover, it leads to a non-productive cycle of work. Most companies have Safety and Health as one of their strategic objectives and a reactive / breakdown approach goes directly against this objective. This negatively impacts a companyâs RONA (Return on Nett Assets) which in return reduces shareholder value. There is no initial cost associated with reactive maintenance, and it does not require maintenance planning which involves time and labor resources. Maintaining your machinery before failures can increase asset life expectancy. Emergency repairs cost as much as 5 to 7 times more than planned preventive work, which can obviously have a huge impact on the bottom line. Proactive is determined by what we are doing pre-results. For more information on how Prometheus Group can help your organization reach this 80/20 goal, Â request a demo of Prometheus Planning & Scheduling. Being proactive in business is about anticipating and preparing for changes and events that can affect your business positively or negatively. Persistent non-delivery or late delivery of orders can have the knock-on effect that key customers lose confidence in the organization and may go to other suppliers or demand discounts / raise penalties which can cost the organization millions. Â Equipment that often/sporadically breaks down reduces the trust between maintenance and production. Disadvantages of reactive maintenance Expensive. Infographic: What do Maintenance Professionals REALLY think about industrial IoT? Often, they need to wait for equipment to be cleared and permits to be issued. This means the team focused on preventive maintenance can stay focused on preventive maintenance and try isolating issues before they occur. 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. Reactive repairs tend to take longer due to several factors including time to diagnose, travel time, time to pull parts from stores or submitting emergency orders, time to pull correct manuals and schematicsâ¦ etc. With reactive approach, failures occur unexpectedly, workers run around looking for the correct safety manuals and documentations as well as spare parts and tools. Also, one must consider that with planned maintenance, failures might have been avoided. Setting in place solid planning & scheduling to support this objective is key to achieving these returns. However, there is a point where the law of diminishing returns takes over. Planned maintenance can be written into the production schedule whereas unplanned repairs can happen anytime. When you plan your maintenance activities you have time to analyze, consider and take actions based on previous data and production schedule. A minor issue could quickly turn into a major system repair. Reactive is defined by what happens after the results. While reactive maintenance might make sense from the first sight (repairing only when failures occur) it shouldn’t be your main strategy. With reactive maintenance everything must be more urgent and workers are under pressure. Preventing failures of assets under load, however, has been proven to be far more cost effective with the same production output. The benefits of condition-based maintenance (CBM) are now as clear as they ever were. When equipment is not properly maintained, it uses more energy. 11 Disadvantages of a Reactive Maintenance Program In our previous blog, Reactive vs Preventive vs Predictive Maintenance , we defined Reactive Maintenance as a strategy of repairing parts or equipment only after the asset has broken down or been run to the point of failure. Within both of these, proactive and reactive, there needs to be a balance of consequences to give weight to the sense of accountability, reinforcing the positive and addressing the negative. It can be an appealing process because it seemingly offers the maximum utilization and in turn maximum production output, of the asset by using it to its limits. This is what is called the maintenance death spiral. If you do it the right way, your organization will reap the benefits.... Lubrication. Reactive vs Preventive vs Predictive Maintenance, request a demo of Prometheus Planning & Scheduling. Capturing these nine metrics are the foundation for analyzing the effectiveness of your planning and scheduling process.