Proactive vs. Reactive Maintenance

Why is maintenance important?

All manufacturing equipment will sooner or later need maintenance. Therefore, it is a critical responsibility for maintenance engineers and plant operators to make sure everything is running smoothly and to maximize the production effectiveness on plant. A single breakdown can bring the production to an abrupt and expensive halt and if handled poorly, it can become a very costly incident. Therefore, it is important to take action and make the right decisions when it comes to maintenance. The two maintenance strategies are both ways to keep the production going, but one is taking action before a potential breakdown, where the other focuses on replacing or repairing equipment once it stops working and needs immediate assistance to be able to continue the production – the last mentioned can become very expensive over time, as production may not be able to continue until the failure is located and the spare parts have been ordered and repaired or replaced.

What is reactive maintenance?

Reactive maintenance is as the word suggests, reacting when maintenance is needed. Here the focus is to restore the manufacturing equipment to normal operation after a breakdown by replacing or repairing faulty parts and components. This strategy makes sense for equipment, which are easily changed and replaced such as light bulbs and other inexpensive parts. But unfortunately, only a small portion of failing machinery does not affect high-value assets. Unplanned repairs are often more complicated, and if the responsible maintenance engineers or plant operators are unprepared with little or no prior maintenance invested up to that point, a breakdown most certainly means downtime and lost production and perhaps even safety and environmental risks.

What is proactive maintenance?

Proactive maintenance is a preventative approach that aims to anticipate machine failures or defect equipment before they occur. By determining the roots of potential failures, it is possible to identify and thereby eliminate breakdowns caused by deteriorating equipment conditions. With a proactive maintenance strategy, the maintenance will be scheduled to have inspections on a regular basis and ensure the equipment is operating within parameters to minimize or completely eliminate breakdowns. The proactive maintenance is also referred to as a preventive maintenance. While the plant will experience benefits as noticeable downtime, improved safety and energy savings, it will also optimize equipment efficiency as well as extend operating life of equipment, enhance better planning for spare parts and labor, and all in all improve customer service through reliable and more efficient production.

Why you need EAM system (proactive maintenance) to track, analyze and help?

The proactive EAM system is a solution that gives you the ultimate overview of where you should have your attention, as it otherwise can be overwhelming to track down potential upcoming failures in the equipment. By tracking down and analyzing on under-performing equipment or is known to have a certain lifespan before a breakdown occurs, the EAM system notifies maintenance engineers and plant operators before the production experiences failures. By reducing unplanned downtime and thereby maximizing uptime, you can reduce capital expenditure and make sure everything at your plant is running smoothly as planned.

How to get started?

Our goal is to help our customers towards an efficient and well-maintained production sight. With OPTIWARE EAM solution you will be assured a reliable and high-quality proactive maintenance system that will help you minimize unplanned repairs, extend the life of your assets and most importantly; customized to fit your organization’s specific needs. Book a web demo and get in touch with one of our solution specialists to learn more about our EAM solution and how this proactive maintenance system can benefit your specific needs.