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Reactive maintenance VS Proactive maintenance?

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Question added by LABIB KOOLI , Director of the Sectoral Center for Training in Hotel Technologies at Southern Hammamet , Tunisian Vocational Training Agency (ATFP)
Date Posted: 2015/02/03
Elke Woofter
by Elke Woofter , Project Assistant , American Technical Associates

Proactive maintenance is a preventive maintenance strategy for maintaining the reliability of machines or equipmentThe purpose of proactive maintenance is to view machine failure and similar problems as something that can be anticipated and dealt with before they occur.

Proactive maintenance consists of:

  • Preventive maintenance
  • Predictive maintenance

Because proactive maintenance methods are currently saving industries of all sizes thousands, even millions, of dollars on machine maintenance every year.

Reactive maintenance (also known as "breakdown maintenance") are repairs that are done when equipment has already broken down.

Reactive maintenance focuses on restoring the equipment to its normal operating condition. The broken-down equipment is returned to working within service specifications by replacing or repairing faulty parts and components. Emergency repairs cost3 to9 times more than planned repairs, so maintenance plans that rely on on reactive maintenance are generally the most expensive. Breakdown maintenance is so expensive because shutdowns happen during production runs (instead of pre-scheduled maintenance shutdowns during downtimes); because expedited shipping for spare parts costs much more than regular shipping; and because maintenance staff is often forced to work overtime to repair machinery.

Reactive maintenance is the response to work requests or identified need, usually identified by operations because a piece of equipment is broken or down. Response time to the calls and mean time to repair are the main objectives of this philosophy. The goal is to get it running as quick as you can to get the downtime down to an acceptable level. This is the approach of most organizations today. It may even incorporate what is termed as a preventive maintenance program and may use proactive technologies but only to identify and deal with symptoms of equipment failures.

The proactive approach responds primarily to equipment assessment, root cause analysis, and predictive procedures. The purpose of this philosophy is to predict and prevent failures before they occur. When the failure is initiated and found, the parts are order and the work is planned, scheduled, and executed during an outage instead of a downtime situation. The overwhelming majority of corrective, preventive, and modification work is generated internally in the maintenance function as a result of inspections and predictive procedures by both operations and maintenance departments. The goals of this method are zero breakdowns, continuous asset performance to established specifications, extended asset life and continuous improvement.

Deleted user
by Deleted user

reactive mainenance is responding to a problem after it happens ie. a toilet floods, you react by unplugging it. Cyclical maint ( or preventative maintenance) is maintenance done routinely at fixed intervals to prevent a problem from arising. ie cleaning drain traps twice a year to prevent the toilets from plugging 

MANSOOR AHMAD S/O ABDUL GHAFOOR
by MANSOOR AHMAD S/O ABDUL GHAFOOR , Asst.Plant Incharge (Power Plant ) , KSF Tri Zone Industry Pvt. Limited 24km Sheikhupura Road Lahore

Reactive maintenance (also known as "breakdown maintenance") are repairs that are done when equipment has already broken down.

Reactive maintenance focuses on restoring the equipment to its normal operating condition. The broken-down equipment is returned to working within service specifications by replacing or repairing faulty parts and components. Emergency repairs cost3 to9 times more than planned repairs, so maintenance plans that rely on on reactive maintenance are generally the most expensive. Breakdown maintenance is so expensive because shutdowns happen during production runs (instead of pre-scheduled maintenance shutdowns during downtimes); because expedited shipping for spare parts costs much more than regular shipping; and because maintenance staff is often forced to work overtime to repair machinery.

Proactive maintenance is a preventive maintenance strategy for maintaining the reliability of machines or equipmentThe purpose of proactive maintenance is to view machine failure and similar problems as something that can be anticipated and dealt with before they occur.

Proactive maintenance consists of:

  • Preventive maintenance
  • Predictive maintenance

Because proactive maintenance methods are currently saving industries of all sizes thousands, even millions, of dollars on machine maintenance every year.

Ridha SAIDANI
by Ridha SAIDANI , Maintenance Manager , SOMIPHOS / Technical Direction

Reactive maintenance : 

The oldest maintenance approach is reactive, or "run-to-failure." Equipment isn't repaired or replaced until it breaks.

Companies that rely solely on reactive maintenance find they have:

• Costly downtime. Equipment fails with little or no warning, so the process could be down until replacement parts arrive, resulting in lost revenue.

• Higher maintenance costs. Unexpected failures can increase overtime labor costs, as well as expedited delivery of replacement parts.

• Safety hazards. Failure with no warning could create a safety issue with the failing equipment or other units that might be affected.

 

Preventive maintenance :

The preventive maintenance philosophy is also known as time-based or planned maintenance.

The goal of this approach is to maintain equipment in a healthy condition. Selected service and part replacements are scheduled based on a time interval for each device — whether it needs it or not. 

Vinod Jetley
by Vinod Jetley , Assistant General Manager , State Bank of India

“You know you are in Reactive Maintenance When”:

  1. … you are performing PM on equipment that continues to break down.
  2. … on a breakdown you hear “hurry up we need to get running”.
  3. …when the top metrics used to manage the maintenance process are: # of breakdowns, PM Compliance, and cost.
  4. …when a breakdown occurs and you hear the management state: “this breakdown must not happen again”.
  5. …maintenance is not seen as an equal partner with production.
  6. …the plant manager or production manager defines the priority of maintenance work on a “down day”.
  7. …maintenance cost continues to rise even after cost reductions strategies have been applied.
  8. …the maintenance staff is frustrated and the good maintenance techs are leaving to work for other companies.
  9. …maintenance cost as a % of Replacement of Asset Value is not known and truly not understood.

Wolf Klaas Kinsbergen
by Wolf Klaas Kinsbergen , Managing Director, Designer , ingenieursbureau KB International NV

solve the problems and the costs versus think ahead

Deleted user
by Deleted user

Combination of the two options for the best results

Emergency maintenance times Haddou emergency problems

 

Regular maintenance ensures sustainability

Mohamed Hamdy Kamal Riad
by Mohamed Hamdy Kamal Riad , Senior Solution Architect , IBM

                   Agree with  Elke Woofter                                    .                     

 

Deleted user
by Deleted user

Proactive. Reactive maintenance can also mean cleaning up the mess.

LABIB KOOLI
by LABIB KOOLI , Director of the Sectoral Center for Training in Hotel Technologies at Southern Hammamet , Tunisian Vocational Training Agency (ATFP)

Excellent answer from Elke ! 

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