Breakdown Maintenance, also known as corrective maintenance or run-to-failure maintenance, is a reactive approach where maintenance activities are performed only after equipment or assets have failed or malfunctioned.
Breakdown Maintenance is often used when the cost of preventive maintenance outweighs the cost of occasional repairs, or when equipment failure doesn't pose significant risks, such as in non-critical or easily replaceable assets.
Advantages include reduced maintenance costs (since maintenance is performed only when needed), minimal planned downtime, and the ability to extend asset lifespans by allowing components to reach their natural end of life.
Disadvantages include higher overall costs due to unexpected downtime, decreased equipment reliability, potential safety hazards, and the risk of catastrophic failures that could disrupt operations.
In specific situations, Breakdown Maintenance can be cost-effective, especially for non-critical assets with low replacement costs. However, it's generally not recommended for mission-critical equipment.
Breakdown Maintenance can lead to reduced asset reliability because it doesn't address wear and tear or early signs of degradation that could be detected and mitigated through preventive maintenance.
Predictive Maintenance (PdM) technologies, like condition monitoring and data analytics, can help minimize Breakdown Maintenance by identifying potential failures before they occur, allowing for planned repairs.
Breakdown Maintenance is typically suitable for less critical equipment with low operational or safety risks. For vital or complex assets, preventive or predictive maintenance is often preferred.
Breakdown Maintenance may be appropriate for:
- Non-critical office equipment like printers.
- Non-essential building facilities like decorative lighting.
- Assets with very low failure consequences or readily available replacements.
To optimize Breakdown Maintenance, organizations can:
- Prioritize assets based on criticality.
- Implement condition monitoring for early failure detection.
- Plan for quick repairs to minimize downtime.
- Maintain a reliable inventory of spare parts.
- Continuously assess the cost-effectiveness of this approach.
Yes, Breakdown Maintenance can have safety and environmental implications, especially if asset failures pose risks to personnel or the environment. Adequate risk assessments and safety precautions are essential when using this strategy.