What is Condition-Based Maintenance?

The evolution of Condition-Based Maintenance

What is reactive maintenance?

‘If it isn’t broke, don’t fix it’ is an established maxim many industrial sites still use. However, there are other

approaches to maintenance that can be taken. While this style of maintenance, termed “reactive maintenance”,

has appeal, it also has large risks. Reactive maintenance does not require any upfront or ongoing costs and few,

if any, dedicated personnel.

However, when machinery does break, the impact can be severe and often requires immediate attention. Several

issues can arise from this situation, including limited human resources and significant delays in sourcing replacement

parts. As well as, unexpected downtime costs that can amount to millions of dollars.

The simplest example would be the light bulb – it is only replaced when it blows. On the other hand, it is not a

philosophy that scales well. The larger or more complex the equipment, the greater the consequence of it not

working as it should. A Plant Engineering Maintenance Study indicated that 61% of manufacturing companies

still used reactive maintenance for at least part of their operations.

A scheduled maintenance programme should be specific to an industrial site and all the equipment within it. You can

build this programme using all assets' history data, including maintenance records, breakdown details, and running

performance. This data can also come from the original equipment manufacturer (OEM) for new equipment. The chance

of machine failure as well as the cost of maintenance and repairs will be reduced by this programme.

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