7 Disadvantages of a Reactive Maintenance Program

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.

Why Reactive Maintenance is Not Preferred Over Preventive Maintenance

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.

Seven Disadvantages of a Reactive Maintenance Program

  1. Increased long-term costs:
    Reactive maintenance tends to cause higher costs associated with emergency repairs since the repair has to be done urgently. For example, the costs of rush repairs associated with a failure in a key machine during peak production hours will add up quickly.
  2. Unpredictable equipment downtime:
    Unpredictable equipment downtime with a reactive maintenance strategy result in unscheduled equipment failures, which may lead to disruptions along the production lines. This uncertainty can really hurt revenue and customer satisfaction when delivery schedules are delayed.
  3. Safety risks:
    Additional pressure to perform the emergency repairs may lead technicians to ignore safety measures, increasing the possibility of workplace accidents. For example, if technicians rush to perform repairs without proper checks, it may result in malfunctioned equipment that could jeopardize the safety of workers.
  4. Reduction of equipment life:
    If proper regular maintenance is not performed, then equipment will tend to deteriorate with time due to wear and tear. This would then reduce the asset life span and increase the frequency of asset replacement. This in turn increases capital expenditures in the long run.
  5. Operational disruptions:
    Most of the time, reactive maintenance interferes with planned preventive work. Scheduled maintenance tasks are sidetracked by emergency repairs, sometimes contributing to a “maintenance death spiral,” whereby future failures are more likely when preventive measures are not carried out.
  6. Inefficient use of resources:
    Technicians may spend excessive time diagnosing problems and sourcing parts for emergency repairs instead of focusing on planned tasks. This inefficiency can lead to wasted labor costs and reduced productivity across teams.
  7. Negative impact on production schedules:
    Frequent unplanned breakdowns disrupt production schedules, causing delays that can ripple through the supply chain. For instance, if a key piece of machinery fails unexpectedly, it may halt production entirely until repairs are completed.

The Balance Between Reactive and Preventive Maintenance

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.

How a Mobile EAM Solution Helps Foster Good Preventive Maintenance Practices

A mobile EAM solution will, no doubt, take your preventive maintenance to a whole new level. This is evidenced by the following reasons:

  • Real-time monitoring: Helps monitoring of equipment health in real time, so you are able to detect a problem well before it actually happens.
  • Streamlined work orders: Technicians can receive work orders directly on their mobile devices, reducing delays in communication and ensuring timely responses to scheduled tasks.
  • Data analytics: By analyzing historical data related to equipment performance and failure patterns, an EAM solution provides insights into when and how preventive maintenance should be carried out.
  • Improved resource allocation: With better visibility into asset conditions and repair histories, you can allocate resources more effectively between preventive and reactive tasks.

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.

Final Thoughts

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.

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