In brief
Reactive maintenance is a strategy in which action is only taken after a failure; components are deliberately run until they break down.
Contents
What is Reactive maintenance?
With reactive or breakdown maintenance, no targeted measures are taken before damage occurs. Only when a component fails is it repaired or replaced. The approach is known as run-to-failure, and the action taken after the failure as corrective maintenance. EN 13306 also uses the term corrective maintenance.
The strategy makes sense where a failure has minor consequences: for inexpensive parts that can be replaced quickly, for equipment with built-in redundancy, or for components whose condition can neither be measured nor sensibly planned in intervals. Typical examples are lamps, simple fuses or small parts held in stock. As an unplanned main strategy for important equipment, however, it is risky. Failures occur at inconvenient times, cause consequential damage to other components, tie up staff at short notice and lead to unplanned production interruptions.
For procurement, reactive maintenance often means emergency purchasing: parts have to be found under time pressure, express surcharges accepted and quality checks shortened. The better part data and sources of supply are maintained in advance, the shorter the downtime.
In practice: maintenance and procurement
Anyone who deliberately runs certain components until they fail should keep their spare parts in stock or know sources that can supply at short notice. For the emergency enquiry, the manufacturer part number, photos and quantity should be ready to hand immediately.
Synonyms and abbreviations: breakdown maintenance · run-to-failure · corrective maintenance · firefighting maintenance
Frequently asked questions
When does reactive maintenance make sense?
It makes sense when a failure causes only low costs and no safety risks, the part is inexpensive and quick to replace, or the equipment has built-in redundancy. In that case, preventive servicing or condition monitoring costs more than it saves. It is important that this decision is made deliberately and that the spare part is available.
What are the risks of reactive maintenance?
Failures come without warning and often at the worst possible moment. A defective component can cause further damage, for example a seized bearing damaging the shaft and housing. On top of this come unplanned production losses, overtime and expensive rush purchases. For safety-relevant components, the approach is generally unsuitable.
What is the difference between reactive and preventive maintenance?
Reactive maintenance only intervenes after a failure. Preventive maintenance acts beforehand by servicing or replacing parts at fixed intervals. Preventive measures are easier to plan but also incur costs for parts that would still work. Many companies combine both strategies depending on how important the equipment is.