Breakdown maintenance, also known as run-to-failure maintenance, occurs when an asset fails completely and must be repaired to resume operation.
In many cases, failure maintenance is the default maintenance strategy, especially for organizations that rely on reactive maintenance.
But sometimes it's also the right strategy.
When should I use Roadside Maintenance?
Breakdown maintenance can be planned or unplanned. Maintenance professionals are very familiar with unplanned outages - those are the ones that cause the anxious calls.
But sometimes an organization may choose to fail an asset. You can use run-to-failure maintenance when there is no risk to safety from a failure. Some of these assets can be light bulbs, fuses, bolts, hand tools, pumps, batteries, etc. There are many benefits to breakdown maintenance.
You can choose breakdown maintenance as a strategy if the asset…
- has cheap parts that are easy to replace
- is not critical to operations
- cannot be replaced due to lack of access
- is disposable
- is designed to have a short lifespan
When Roadside Maintenance is not a suitable option,Preventive maintenance softwarecan help reduce business interruptions.
How Can CMMS Software Help?
Because CMMS software collects data on the type and frequency of failures, it can provide some insight into future events. It also lets you know if the failure maintenance procedure is really the right strategy for a particular asset.
Breakdown Maintenance Example
Suppose you have a machine with a fuse that blows every 9-10 months. Your organization uses this asset infrequently. It does not directly affect production. You track repairs to this asset with CMMS software, as you would any asset. Over time, you gather information from work orders about the time between failures, the parts needed, and any instructions or other details from previous replacements.
You can use that information to ensure that you have quick and easy access to the part when the time comes, and that the technician responsible for replacement has all the information at their fingertips.
Just as you plan for scheduled maintenance, you also need to plan for run-to-failure maintenance. This plan states who is responsible for the work, which parts they need and which tasks they have to perform. The only difference between scheduled scheduled maintenance and scheduled failure maintenance is your knowledge of when the failure maintenance will be performed.
Do you use run-to-failure maintenance? Leave a comment orContact us.
What does breakdown maintenance mean? ›
Breakdown maintenance, sometimes called run-to-failure maintenance, occurs when an asset completely breaks down and needs repair to resume operation.What is breakdown maintenance with example? ›
The breakdown maintenance definition is a type of maintenance that involves using a machine until it completely breaks down and then repairing it to working order. For example, this type of maintenance would occur if you wait until a machine stops working before fixing it.What is breakdown time in maintenance? ›
Breakdown time is downtime that results from the equipment breaking down. You'd start counting from the time the asset fails to the time you manage to get it up and running again. Equipment downtime, on the other hand, is any amount of time in which a piece of equipment is offline.Why is breakdown maintenance? ›
Breakdown maintenance is maintenance performed on a piece of equipment that has broken down, faulted, or otherwise cannot be operated. The goal of breakdown-maintenance is to fix something that has malfunctioned. To the contrary, preventive maintenance is performed in order to keep something running.What is another term for breakdown maintenance? ›
Breakdown maintenance, also referred to as corrective maintenance, is a strategy that performs maintenance tasks only after an asset fails.What are 5 examples of maintenance? ›
- Preventive Maintenance Equipment Inspections. ...
- Clean Equipment Regularly to Minimize Dirt and Dust. ...
- Lubricate Rotating Parts to Prevent Premature Wear. ...
- Check Machinery Power to Optimize Energy Efficiency. ...
- Repair or Replace Equipment Before it Fails.
Differences between preventive and breakdown maintenance
Preventive maintenance (PM) is work that is scheduled based on calendar time, asset runtime, or some other period of time. Breakdown maintenance (BM) is work that is only performed when a piece of equipment breaks down or has a downtime event.
What Is the Difference Between Corrective and Breakdown Maintenance? Corrective maintenance focuses on fixing and repairing faulty assets and equipment. Breakdown maintenance is performed on equipment that is broken or otherwise stopped in such a way that it is no longer operational.Which activity is performed in breakdown maintenance? ›
What is Breakdown Maintenance? As the name suggests, breakdown maintenance is the corrective maintenance action required to be undertaken in case of equipment failure or emergency maintenance. This type of maintenance management is performed by maintenance teams only when it is urgent and impacts productivity.
Perhaps the most important difference in 'downtime vs breakdown' is the type of maintenance performed. Once equipment or machine failure has occurred, only reactive maintenance is used – in other words, corrective maintenance and emergency maintenance.What are the 3 main types of maintenance? ›
- Corrective Maintenance.
- Preventative Maintenance.
- Predictive Maintenance.
For example, you may have a trolley or forklift that is not inspected, but breaks down. Fixing such an item is unplanned corrective maintenance. Other examples include burst water pipes that need replacing quickly. However, unplanned maintenance can happen even when a maintenance plan is in place.How do you prevent breakdowns? ›
- Socialize more with friends and family. ...
- Get more physical exercise, a great way to reduce stress.
- Practice relaxation techniques, like meditation, journaling, or breathing exercises.
- Eat a healthy diet.
- Get enough sleep every night.
- Take time to do enjoyable activities.
- Spend time alone if needed.
Breakdown is the result of failure and the effect that failure has over the failure developing period. For example, if the temperature of your electric motor remains too high, it can cause the shaft to snap, creating a breakdown.What is called breakdown? ›
: failure to progress or have effect : disintegration. a breakdown of negotiations. : a complete loss of physical, mental, or emotional vitality : a physical, mental, or nervous collapse. d. : the process of decomposing.What are the 4 types of maintenance? ›
Preventive maintenance – includes regular and periodic (time-based) schedules. Corrective maintenance – occurs when an issue is noticed. Predetermined maintenance – follows a factory schedule. Condition-based maintenance – occurs when a situation or condition indicates maintenance is needed.What are the 4 key elements of maintenance? ›
- Reactive Maintenance (RM) Reactive maintenance, sometimes discussed as run-to-failure, involves sending a team to repair assets only after they fail. ...
- Preventive Maintenance (PM) ...
- Predictive Maintenance (PdM) ...
- Reliability-Centered Maintenance (RCM)
The maintenance phase of the software development life cycle is where the software is monitored to ensure it continues to function as it was designed to, and repairs or upgrades are performed as needed. The maintenance phase occurs once the software is fully operational.Is breakdown maintenance proactive? ›
Proactive maintenance will look at why machines break down.
You should have proactive maintenance in your maintenance plan. This is very true if you are doing a lot of corrective or unplanned maintenance. Even if a lot of preventive maintenance is being done, it can reduce breakdowns and unwanted work.
Methods. The steps of corrective maintenance are, following failure, diagnosis – elimination of the part, causing the failure – ordering the replacement – replacement of the part – test of function and finally the continuation of use. The basic form of corrective maintenance is a step-by-step procedure.What are the two types of downtime? ›
Downtime falls into two categories: planned and unplanned. Planned downtime is notable because it offers advanced warning and gives users a chance to prepare. Planned downtime is usually done for upgrades or maintenance to the network infrastructure.How do you calculate breakdown time? ›
- total working time = 24 hours.
- total breakdown time = 3.5 hours (1 + 2 + 0.5)
- number of breakdowns = 3.
Downtime has many causes, including shutdowns for maintenance (known as scheduled downtime), human errors, software or hardware malfunctions, and environmental disasters such as power outages, fires, flooding or major temperature changes.What are the three key components of maintenance management? ›
The three major elements of maintenance management systems are; risk assessment, maintenance strategy selection and maintenance task interval determination.Which type of maintenance is most effective? ›
It is regularly performed on a piece of equipment to lessen the likelihood of it failing. It is performed while the equipment is still working so that it does not break down unexpectedly.
Preventive maintenance (or preventative maintenance) is maintenance that is regularly and routinely performed on physical assets to reduce the chances of equipment failure and unplanned machine downtime that can be very costly for maintenance teams and facility managers.What are examples of run to failure maintenance? ›
A common example of run-to-failure maintenance is the maintenance plan for a general-purpose light bulb. The bulb is allowed to run until it fails. At this time, the plan to fix the asset is carried out. A new light bulb is obtained from stocks and replaced at a convenient time.What is the difference between routine maintenance and breakdown maintenance? ›
Preventive maintenance identifies any issues before equipment failure or downtime, through routinely scheduled maintenance. Breakdown maintenance works by running equipment until it breaks down, in which case repairs and maintenance are performed.What is the difference between breakdown and emergency maintenance? ›
Emergency maintenance, also known as breakdown maintenance, is maintenance required when an asset or piece of equipment suffers an unexpected breakdown or change in condition that results in an immediate threat to health and safety or could cause serious property damage.
- Corrective maintenance.
- Preventive maintenance.
- Risk-based maintenance.
- Condition-based maintenance.
Field-level maintenance is an on- system or near-system repair process that returns equipment to the user. Sustainment-level main- tenance is an off-system repair pro- cess that returns equipment to the supply system.What is breakdown maintenance and its advantages and disadvantages? ›
This is where assets are deliberately run until they fail. When failure occurs, reactive maintenance is performed to fix the asset and return it to full operation. This approach is common when equipment failure doesn't significantly affect operations or productivity.
: failure to progress or have effect : disintegration. a breakdown of negotiations. : a complete loss of physical, mental, or emotional vitality : a physical, mental, or nervous collapse.Why does breakdown mean? ›
a breaking down, wearing out, or sudden loss of ability to function efficiently, as of a machine. a loss of mental or physical health; collapse. Compare nervous breakdown. an analysis or classification of something; division into parts, categories, processes, etc.