Corrective Maintenance, also known as breakdown maintenance or reactive maintenance, involves addressing equipment or system issues after they have already occurred, with the primary goal of restoring functionality and minimizing downtime.
Corrective Maintenance is used when equipment or systems fail unexpectedly. It is essential for addressing immediate issues and getting operations back on track quickly.
Corrective Maintenance involves the following steps:
- Detecting Failure: Equipment failures are identified through monitoring systems, observations, or when users report problems.
- Diagnosis: Technicians assess the root cause of the failure and determine the necessary repairs.
- Repair or Replacement: Technicians perform repairs, replace faulty components, or restore the system to working condition.
- Verification: The repaired equipment or system is tested to ensure it functions properly.
Relying solely on Corrective Maintenance can lead to increased downtime, production delays, higher maintenance costs due to emergency repairs, and potential safety risks.
Corrective Maintenance is suitable for non-critical systems, assets with low maintenance impact, or situations where the cost of preventive maintenance outweighs the cost of reactive repairs.
Corrective Maintenance does not prevent equipment failures, and it can result in unexpected downtime, production losses, and potential damage to other components due to cascading failures.
While Corrective Maintenance may be unavoidable in certain cases, organizations can manage it more effectively by:
- Implementing predictive and preventive maintenance strategies where feasible.
- Monitoring equipment health and performance to detect early signs of potential failures.
- Maintaining an inventory of critical spare parts for quicker repairs.
- Having well-trained maintenance teams capable of swift response.
Corrective Maintenance is one of the least preferred practices in Total Productive Maintenance (TPM), a comprehensive approach that aims to minimize unplanned downtime and improve overall equipment efficiency.
Organizations can transition by:
- Conducting a cost-benefit analysis of preventive and predictive maintenance.
- Implementing condition-based monitoring to identify early signs of equipment degradation.
- Creating a culture of preventive maintenance and investing in training.
Reducing reliance on Corrective Maintenance leads to benefits such as improved asset reliability, reduced downtime, increased equipment lifespan, better resource allocation, and enhanced overall operational efficiency. It also enhances safety and reduces the risk of cascading failures.