In the field of maintenance management, a reactive maintenance program usually referred to as "breakdown maintenance" is a program where repairs are done only when something has failed. This usually appears to be very cheap, but it will result in major long-term effects.
According to a study by IBM, organizations that rely heavily on reactive maintenance can face increased operational costs and reduced equipment lifespan, with estimates suggesting that unplanned downtime can cost companies up to $260,000 per hour in lost productivity and revenue.
This blog will discuss the disadvantages of a reactive maintenance program, why it is usually not as popular as preventive maintenance, and how striking a balance between the two approaches can yield better results. We will also be discussing how mobile EAM solutions can further improve preventive maintenance practices.
A reactive maintenance program is often not the preferred choice compared to preventive maintenance due to its inherent unpredictability and higher costs. Preventive maintenance involves scheduled inspections and routine repairs aimed at preventing equipment failures before they occur. This proactive approach not only extends the life of assets but also minimizes unexpected downtimes and associated costs. In contrast, reactive maintenance leads to emergency repairs that are typically more expensive and time-consuming, disrupting production schedules and impacting overall operational efficiency.
While reactive maintenance does have its negative aspects, it is also important to point out that no amount of planning can escape some reactive work in any maintenance strategy. The principles of balance, often understood as the 80/20 rule, can help reach an optimum in your operations. The principle here is that 80% of your activities are directed at prevention, and you remain free to use 20% on reactive work when necessary.
By observing this balance, you will be investing the bulk of your resources in preventing failures, yet you will be adequately prepared against unforeseen ones. This will also help reduce the risks involved in unwarranted downtime and contribute to higher operational efficiency.
A mobile EAM solution will, no doubt, take your preventive maintenance to a whole new level. This is evidenced by the following reasons:
By leveraging technology through a mobile EAM solution, you enhance your ability to maintain equipment proactively while minimizing the need for costly reactive repairs. In this context, look for a cutting-edge, yet a cost-effective mobile EAM solution like that offered by Propel Apps to satisfy your specific industrial requirements.
This mobile EAM solution from Propel Apps ticks all the right features as discussed above and offers much more to perfectly sync with your industrial eco-system. By adopting this solution, you can transform plant maintenance and asset management operations using Oracle EAM, SAP Plant Maintenance, design thinking, and enterprise mobile implementations. To know more about this solution, schedule a free demo with us.
In the long run, while reactive maintenance might sound very easy in dealing with equipment failure, its long-term disadvantages certainly outnumber its advantages on the positive side. Some of the challenges that come with this approach include increased costs, unpredictable downtimes, safety risks, and operational inefficiencies. Give priority to preventive maintenance augmented by tools such as mobile EAM solutions to realize a more efficient and effective maintenance strategy that will protect your assets and further enhance overall productivity.
As you go about your daily business, whether you are a maintenance or production manager or technician, think about the implications of your maintenance strategies; the right mix of being proactive in planning and responsive in action will provide the key to operational excellence.
