Overcoming Reactive Maintenance Challenges | Quality Digest

Whether your equipment relies on high-pressure hydraulics and spinning rotors or high-speed blades and abrasive chemicals, malfunctions can cause injuries to operators and pose an environmental hazard. Here, a reactive maintenance policy may be unsafe, and can even expose you to legal liability.

How can preventive maintenance help?

Reactive maintenance strategies don’t include measurements for failure modes, mean time between failures (MTBF), or total cost of ownership (TCO).

How can preventive maintenance help?

With a reactive maintenance workflow, maintenance is only performed after a malfunction or failure has already occurred. This minimizes initial costs and simplifies maintenance requirements while the parts or equipment in question are running. However, with reactive maintenance, little is done to prevent the occurrence of breakdown or failure. As a result, malfunctions often lead to significant downtime.

For more critical assets, a preventive approach to maintenance is typically best for maintaining operating conditions.

Reactive maintenance management vs. preventive maintenance management

Published: Monday, March 4, 2024 – 12:02

So please consider turning off your ad blocker for our site.

How can preventive maintenance help?

Published Feb. 15, 2024, by Limble.

منبع: https://www.qualitydigest.com/inside/risk-management-article/overcoming-reactive-maintenance-challenges-030424.html

1. Managing spare parts inventory

How can preventive maintenance help?

Despite their short-term benefits, purely reactive maintenance programs are actually costly, inefficient, and potentially even hazardous. By contrast, preventive maintenance strategies are proven to:
• Eliminate work stoppage and lost productivity caused by equipment downtime
• Reduce the frequency, cost, and labor hours dedicated to emergency repairs
• Improve maintenance operations and extend the life span of your assets

You can mitigate these risks by incorporating preventive maintenance tools into your inventory management strategy. For instance, a parts management module can help you optimize spare stock levels by providing purchase prompts based on current inventory and disposal advice for parts that remain unused.

3. Handling operational disruptions

Reactive maintenance produces variability in when, how, and why equipment fails. The result is an uneven and scattered approach to initiating maintenance work and resuming normal operation.

Quality Digest does not charge readers for its content. We believe that industry news is important for you to do your job, and Quality Digest supports businesses of all types.

The primary advantage of reactive maintenance is that it’s a cost-effective and uncomplicated way to get the most output from assets before they fail. Although preventive maintenance can minimize long-term costs, it presents upfront costs of its own that some organizations can’t manage.

Risk Management

Overcoming Reactive Maintenance Challenges

How reactive and preventative maintenance differ

Below are five common reactive maintenance challenges as well as tips on how a more proactive approach can help.

Reliable CMMS software assists staff in developing, updating, and storing standardized maintenance procedures so your team is ready with a clearly delineated plan for minimizing downtime and keeping repair costs low when equipment fails.

Using a reactive maintenance strategy can complicate inventory management. When you forego routine inspections or maintenance, it can be difficult to anticipate which spare parts you should hold in stock and in what quantity. Businesses using a reactive maintenance approach risk carrying excess inventory or falling short when critical spares are needed. Either condition can have negative consequences.

You can prepare for shifting technician workloads by integrating smart vendor management software into your maintenance program. An effective vendor management application should allow you to easily track and manage service contracts and contractors and oversee work order management.

Our PROMISE: Quality Digest only displays static ads that never overlay or cover up content. They never get in your way. They are there for you to read, or not.

Sudden and unforeseen breakdowns disrupt the work of machine operators, draw technicians away from routine tasks, and demand the attention and coordination of managers. In other words, this emergency maintenance approach can cause major operational disruptions throughout your organization.

Some of this inconsistency can be mitigated with a well-planned failure maintenance program. A failure maintenance program can also help you counterbalance some of the heavier costs of reactive maintenance, such as the reduced life expectancy of your equipment or the prolonging of unplanned downtime.

Reactive maintenance is a form of physical asset management in which maintenance is only performed on equipment or machinery when it malfunctions or fails entirely. Sometimes referred to as run-to-failure maintenance or breakdown maintenance, reactive maintenance strategies provide the most basic level of asset maintenance and offer a minimum threshold of stability until your organization is prepared to take a preventive approach to maintenance.

By contrast, preventive maintenance strategies, which fall under the umbrella of proactive maintenance, use monitoring and data analysis to plan, schedule, or trigger maintenance activities. These activities are performed proactively as a way to prevent malfunction or failure, minimize the downtime resulting from these events, and extend the life span of your equipment.

Reactive maintenance challenges

You’ll be able to control your spend, streamline communication with service providers, and ultimately connect assets with vendors that are responsible for maintaining them. This puts you in a position to swiftly deploy maintenance, repairs, and task reallocation when equipment failures and other maintenance issues occur. You may also be able to optimize your technician workloads by taking advantage of the calendar-based maintenance services that are often included in your service contract.

A reactive maintenance strategy may reduce your maintenance staffing needs while your equipment is functional. When malfunctions and breakdowns occur, however, your maintenance team’s plans may be thrown into disarray.

This usage-based maintenance strategy can serve as a backstop to prevent excess inventory or a critical shortfall of parts. With a preventive maintenance strategy, you can deploy features like automatic usage tracking, inventory holdings management, traceability, and real-time reporting to keep your spare-parts inventory database up to date.

Reactive, or corrective, maintenance differs from preventive maintenance in many key ways.

Reactive maintenance simply doesn’t allow data-driven insight into asset performance, condition, or health. Business owners who take this approach place their productivity and profitability at the mercy of their equipment.

4. Keeping the workplace safe

How can preventive maintenance help?

In the absence of a full preventive maintenance plan, an FMECA study could help you identify failure modes that pose serious safety risks so you can coordinate maintenance-related work. In essence, this study lets you rank failure risks by their criticality so you can detect, prevent, and reduce the severity of failure.