Breakdown Maintenance, Objectives, Characteristics, Steps, pros and Cons

Breakdown Maintenance, also known as corrective maintenance or run-to-failure maintenance is a reactive approach to maintenance that focuses on addressing equipment failures and restoring assets to working condition after a breakdown has occurred. Unlike preventive or predictive maintenance, which aim to proactively prevent failures, breakdown maintenance involves responding to issues as they arise. While it is a less proactive strategy, it is sometimes necessary, especially for non-critical or easily replaceable equipment. Breakdown maintenance is a reactive strategy that focuses on addressing equipment failures as they occur. While it may be cost-effective for certain non-critical equipment, it comes with drawbacks such as increased downtime and potential for secondary damage. Organizations need to carefully evaluate their assets, considering factors such as criticality, replacement cost, and overall operational goals, to determine whether breakdown maintenance is a suitable approach for specific equipment within their facilities. In many cases, a balanced maintenance strategy that incorporates preventive, predictive, and corrective measures may be more effective in ensuring the reliability and longevity of assets.

Objectives of Breakdown Maintenance:

• Restore Operations Quickly:

The primary objective of breakdown maintenance is to quickly address and rectify equipment failures to minimize downtime and restore operations promptly.

• Cost-Effective for Non-Critical Assets:

Breakdown maintenance may be considered cost-effective for non-critical assets or equipment with low replacement costs. In such cases, the cost of preventive measures may outweigh the benefits.

• Simplify Maintenance Management:

For certain equipment, especially those with low failure consequences, breakdown maintenance can simplify maintenance management by eliminating the need for scheduled preventive tasks.

• Optimize Resource Utilization:

Resources are allocated only when necessary, avoiding routine maintenance costs. This can be advantageous for organizations with limited resources.

Characteristics of Breakdown Maintenance:

• Unplanned Interventions:

Breakdown maintenance is initiated as a response to unexpected failures, and maintenance activities are not pre-planned or scheduled.

• Minimal Preventive Measures:

Unlike preventive maintenance, which involves regular inspections and proactive tasks, breakdown maintenance does not include systematic preventive measures.

• Reactive Approach:

Organizations adopting breakdown maintenance have a reactive approach to equipment issues, addressing problems as they occur rather than preventing them.

• Short-Term Focus:

The focus of breakdown maintenance is often short-term, aiming to quickly resume operations without necessarily addressing the root causes of failures.

Steps in Breakdown Maintenance:

• Identification of Failure:

The first step involves identifying that a failure has occurred. This can be through operator reports, alarms, or other monitoring systems.

• Isolation of Equipment:

Once a failure is identified, the affected equipment is isolated to prevent further damage or safety hazards.

• Diagnosis and Troubleshooting:

Technicians diagnose the cause of the failure and troubleshoot to identify the specific issues that led to the breakdown.

• Repair or Replacement:

After identifying the problem, the necessary repairs or replacements are carried out to bring the equipment back to operational status.

• Testing and Verification:

The repaired or replaced equipment is tested to ensure that it functions properly and meets safety and operational standards.

• Resume Operations:

Once the equipment is verified and deemed operational, it is reintegrated into the production or operational process.

Pros of Breakdown Maintenance:

• Cost-Effective for Non-Critical Equipment:

Breakdown maintenance can be cost-effective for non-critical or easily replaceable equipment where the cost of preventive measures outweighs the benefits.

• Simple Maintenance Management:

It simplifies maintenance management for equipment with low failure consequences, eliminating the need for complex preventive maintenance schedules.

• Resource Optimization:

Resources are allocated only when a failure occurs, optimizing resource utilization, especially for organizations with limited resources.

Cons of Breakdown Maintenance:

• Increased Downtime:

Breakdown maintenance can result in extended downtime as operations are halted until the equipment is repaired, affecting overall productivity.

• Potential for Secondary Damage:

Delayed intervention may lead to secondary damage, causing more extensive and costly repairs than if the issue had been addressed earlier.

• Operational Disruptions:

Unplanned breakdowns can disrupt operations, leading to inefficiencies in production schedules and delivery timelines.

• Safety Concerns:

Depending on the nature of the equipment and the industry, breakdown maintenance may pose safety risks to personnel and the overall workplace environment.