Reactive maintenance is a maintenance strategy in which maintenance and repair activities are carried out only after a problem or failure has already occurred. This approach is based on the principle of “repair as needed” and is often performed without prior planning or regular maintenance intervals.

Difference from “Breakdown Maintenance”

Reactive maintenance and breakdown maintenance mainly differ in terms of scope and focus. Reactive maintenance covers a broader range of issues and refers to performing maintenance and repair activities as soon as a problem or malfunction occurs. This can include minor disruptions as well as complete failures, without prior planning or scheduled maintenance intervals.

In contrast, breakdown maintenance specifically focuses on resolving complete failures or operational shutdowns. This type of maintenance is carried out when a machine or system is no longer functioning and has completely failed. While reactive maintenance aims to address any issues that arise and restore operation as quickly as possible, breakdown maintenance concentrates exclusively on severe faults that affect the entire operation.

Objectives and Benefits of Reactive Maintenance

• Minimal planning requirements: Since maintenance actions are only taken after a failure occurs, no extensive advance planning is required.
• Full utilization of asset life: Machines and systems are used until actual failure, allowing maximum use of invested resources.
• Simple implementation: This approach requires less organizational effort and fewer resources, as maintenance is performed only when needed.

Disadvantages

• Unplanned downtime: Because maintenance only takes place after a failure, unexpected production interruptions may occur, leading to significant costs and delays.
• Higher repair costs: Repairs after a failure are often more expensive than preventive maintenance measures, especially when damage is extensive.
• Safety risks: Failures can lead to hazardous situations, particularly in safety-critical machines and systems.

Typical Measures

• Fault diagnosis: Identification and analysis of the cause of failure in order to determine the necessary repair actions.
• Repair and replacement: Replacement of defective parts or repair of damaged components to restore the functionality of the affected machine or system.
• Recommissioning: After repairs, the machine or system is tested and returned to operation to ensure proper functionality.

Implementation

Reactive maintenance requires fast response times and efficient organization. Key steps include:

• Availability of spare parts: Ensuring that critical spare parts are readily available to minimize downtime.
• Staff training: Maintenance personnel must be able to respond quickly and effectively to failures and carry out repairs.
• Documentation: Recording all failures and repair activities to collect data for future optimization of the maintenance strategy.