The Impact of Unplanned or Reactive Maintenance

Posted by Doug Watt on Mar 3, 2017 11:25:03 AM

The cost of unplanned maintenance activities such as replacing or repairing failed equipment is high; lost production, expensive labor (call outs, overtime) and damaged equipment adds up.

Unplanned maintenance will always be a part of your maintenance strategy but to rely on it solely has a number of disadvantages:

  1. Budget Control – Failures are expensive. Emergency call outs, travel time, labor, parts and hot-shot deliveries result in a paying a premium to fix the problem.
  2. Shorter Equipment Life – Running equipment in less than optimal condition or to the point of failure can reduce the life of the asset.
  3. Bad Actors – Unplanned maintenance will get the equipment up and running but not look at the root cause and will likely result in future failures.
  4. Safety Issues – Unplanned maintenance is often done under a lot of pressure and in a hurry which can result in unwarranted risks.

There is no way to eliminate unplanned maintenance but it can be reduced by implementing a Preventative Maintenance Program. The goal should be a maintenance plan that is 80% planned 20% reactive. Using a Computerized Maintenance Management System (CMMS) to track and report your maintenance activities will help you reach this goal.


Topics: Technology, Software