If you wait until your equipment is already broken before fixing it, getting an emergency repair can cost as much as nine times as much as what you would spend if you had planned your repairs. Reactive maintenance is much more expensive because you have to deal with unexpected production shutdowns while your emergency repair is completed. If you have planned repairs, then they can be scheduled during your maintenance shutdowns. Reacting to problems instead of planning for them is also more expensive because you may need expedited shipping for the parts. This costs much more than obtaining the parts that you need by regular shipping. Finally, reacting instead of planning might have added labor costs because your staff may have to work overtime hours to complete the repairs.
What is planned maintenance?
When you have a pre-planned maintenance schedule, it can minimize work stoppages and prevent the added costs that are involved in making emergency repairs. By planning your repairs, you can continue your operations with minimal interruptions.
Disadvantages of reactive maintenance
There are many disadvantages of only making repairs when your equipment is already broken. If you do not have a planned repair and maintenance schedule, your equipment will not be kept in an optimum condition. As time passes, the systems that have not received regular maintenance will wear down faster, giving them a shorter life expectancy.
Reacting instead of planning your repairs also exposes your company and your workers to safety hazards. Scheduled work allows your technicians enough time to review the safety requirements and the procedures to do the job. When technicians are making emergency repairs, however, they may cut corners to try to get the work done faster. Emergency repairs also tend to take much longer to complete because it may take time to diagnose the problem, find the parts, order them, and find the right schematics and manuals.
Unplanned downtimes are also characteristic of reactive maintenance. These unexpected repairs can occur at any time. When emergency repairs have to be completed, they are normally done at the expense of planned work. The daily work may have to be canceled or delayed. If you have unexpected downtime, it can also cause problems with your production schedule, potentially causing reputational damage and revenue problems.
Since emergency repairs often involve doing the least amount of work that is required to get the equipment running again, there are likely to be future problems and repeated downtimes. Improperly maintained equipment also consumes more energy. Simple maintenance tasks such as changing the filters and greasing the parts can reduce the amount of energy that is consumed by as much as 15 percent.
We can offer you a maintenance plan that can help you to avoid potential unexpected emergency repairs. When you choose our plan, you will receive the following benefits:
- Regular, planned maintenance
- On-site machinery inspection visits
- Affordable repairs for issues that we discover in your systems
We have experienced technicians and inspectors who prioritize helping you to identify problems that could lead to future issues. When you choose our maintenance plan, you will be taking a great preventative measure. To learn more, fill out our contact form or call us today.