What is Breakdown Maintenance? A Detailed Look

Article Written by:

Muthu Karuppaiah

What is Breakdown Maintenance? A Detailed Look

Table of Contents

What is Breakdown Maintenance?

Breakdown Maintenance, also known as Run to Failure (RTF) maintenance, is a maintenance strategy in which maintenance is only performed when equipment has failed. Unlike proactive maintenance strategies such as preventive and predictive maintenance, breakdown maintenance is reactive - action is only taken when a failure has occurred.

Types of Breakdown Maintenance

There are primarily two types of breakdown maintenance:

Unplanned Breakdown Maintenance

This is the most common type of breakdown maintenance where the equipment can operate until it fails; at this point, corrective action is taken.

Planned Breakdown Maintenance

Contrary to its name, this involves allowing equipment to run until it fails, but with a planned strategy for managing failure when it occurs. It's commonly used for non-critical equipment or equipment with redundant counterparts that won't lead to production loss during downtime.

Examples of Breakdown Maintenance

Light bulbs in a factory are allowed to burn out before they are replaced. The failure of a light bulb doesn't halt production, making it a candidate for breakdown maintenance.

A conveyor belt in a distribution center can run until it fails. When it does, the operation is halted, the failed part is replaced, and the conveyor belt is put back into operation.

Benefits of Breakdown Maintenance

A breakdown maintenance strategy can offer the following benefits:

Lower Initial Costs

Since the equipment can run until it fails, there are no upfront costs for maintenance planning and scheduling.

Reduced Maintenance Tasks

Maintenance tasks are only performed when necessary, potentially reducing the overall number of tasks and associated labor costs.

Suitability for Non-Critical Assets

Breakdown maintenance can be an effective strategy for non-critical assets or assets that do not directly impact the production line.

However, it's important to note that while breakdown maintenance might seem cost-effective in the short term, the long-term costs associated with unexpected downtime, potential overtime labor costs, rushed parts shipping, and possible damage to other components can often exceed the costs of a more proactive maintenance strategy.

The Role of CMMS Software in Managing Breakdown Maintenance

While the idea behind breakdown maintenance is to allow equipment to run to failure, managing these failures requires careful planning and prompt response. CMMS (Computerized Maintenance Management System) software like Cryotos can play a critical role here. CMMS can help manage work orders, track failure data, and assist in identifying parts that frequently cause breakdowns; This information can be used to switch from a breakdown maintenance strategy to a more proactive maintenance strategy like preventive or predictive maintenance.

Moving Towards Predictive Maintenance

More organizations are moving towards predictive maintenance strategies in today's technologically advanced industrial environment. By leveraging technologies like IoT, AI , and machine learning, predictive maintenance allows potential failures to be identified and corrected before they occur, significantly reducing the costs associated with equipment breakdown.

Use Case of Breakdown Maintenance

Consider an organization that runs a fleet of delivery trucks. They decide to implement a breakdown maintenance strategy for the tires on their trucks. This decision is based on the understanding that the premature replacement of tires doesn't provide any significant operational advantages, and the failures (i.e., a flat tire) do not lead to a high cost of downtime. The company maintains a stock of spare tires and the tools required for replacement. The change is performed by their in-house maintenance team, thus avoiding costly emergency repairs or outsourcing fees.

Advantages of Breakdown Maintenance

Cost Savings

When applied to the right equipment, this approach can reduce the cost of unnecessary maintenance and premature part replacements.

Simplicity

Breakdown maintenance requires no advanced planning or scheduling. Maintenance is performed only when a failure occurs.

Ideal for Non-Essential Equipment

Breakdown maintenance can be a practical approach for equipment where failure doesn't impact productivity or safety.

Disadvantages of Breakdown Maintenance

Unpredictable Downtime

The main downside of a breakdown maintenance strategy is that equipment can fail without warning, causing unplanned downtime and disruption to the production schedule.

Higher Repair Costs

Failures under full operational stress can often cause extensive damage, leading to more expensive repairs and longer downtime.

Risk of Secondary Damage

When a component fails, it can often cause damage to other parts of the equipment, leading to more extensive repairs.

Safety Concerns

Depending on the nature of the equipment and the failure, breakdown maintenance can potentially lead to safety risks.

It's important to note that breakdown maintenance isn't suitable for all types of equipment, especially critical equipment, where failures can lead to significant operational disruption, safety risks, and higher costs. As a result, many organizations are combining this approach with predictive or preventive maintenance strategies for different types of equipment, leveraging the benefits of each; This is often facilitated by a CMMS system like Cryotos, which can manage and track different types of maintenance strategies across a range of equipment.

Best practices for implementing Breakdown Maintenance effectively while maintaining security are as follows:

Right Equipment Selection

Not all equipment suits a breakdown maintenance strategy. It should only be used for non-critical equipment, where downtime would not significantly impact the business operation or safety.

Risk Assessment

A thorough risk assessment should be carried out for all equipment considered for a breakdown maintenance strategy, including an evaluation of the safety implications of a sudden equipment failure.

Proper Training

Maintenance staff should be trained to safely and efficiently handle emergency repairs. They should be familiar with all the equipment they are responsible for and be able to diagnose and repair problems promptly to minimize downtime.

Availability of Spare Parts

Ensure a ready stock of spare parts is available for equipment under a breakdown maintenance regime; This can significantly reduce the time taken to get the equipment back up and running after a failure.

Maintenance Documentation

Keep accurate and up-to-date maintenance records. These will provide valuable data on equipment failure rates, repair timesa, and costs, which can be used for future planning and decision-making.

Cybersecurity Measures

Ensuring cybersecurity is paramount with the increasing digitalization of maintenance activities and the use of CMMS software. Use secure systems, keep software up to date, regularly backup data, and train staff in cybersecurity awareness.

Emergency Procedures

Have clear procedures for handling equipment failures; This should include communication protocols to keep all relevant staff informed about the situation.

Regular Review

Regularly review and adjust the breakdown maintenance strategy based on actual failure rates, repair times, and costs.

Use of Technology

Utilize CMMS software, like Cryotos, to help manage and document breakdown maintenance tasks efficiently. With features like real-time data analysis, cloud-based accessibility, and predictive analytics, Cryotos not only helps in the effective execution of tasks but also ensures cybersecurity.

Remember, a well-managed breakdown maintenance strategy can offer cost savings for certain types of equipment. However, it should be part of a wider maintenance strategy, including preventive and predictive maintenance approaches.

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