How to Reduce Corrective Maintenance

Your production line grinds to a halt at 2 AM. Critical equipment has failed unexpectedly, and your maintenance team scrambles to locate the necessary parts, tools, and expertise to restore operations. Meanwhile, every hour of downtime costs your business an average of $25,000.

This scenario plays out in facilities worldwide every day.

Equipment failures not only cost money but also compromise productivity, endanger safety, and erode a company’s competitive edge.

When corrective maintenance dominates your maintenance strategy, you’re essentially gambling with your operations.

The worst part? Most of these failures are entirely preventable with the right approach.

The good news is that you can dramatically reduce both the frequency and impact of corrective and reactive maintenance.

This comprehensive guide explores proven strategies to reduce both the occurrence and duration of corrective maintenance activities, helping you regain control of your operations and your budget.

Key Takeaways

• Identify and fix root causes to reduce unplanned repairs.
• Regular training and new tools enable teams to work more efficiently.
• Track results and adjust strategies for better outcomes.

Understanding Corrective Maintenance

Corrective maintenance focuses on repairing equipment or systems after they have malfunctioned. It is essential in keeping machines and processes running, but can become costly and time-consuming if not appropriately managed.

This type of maintenance is necessary when emergencies occur and routine upkeep is insufficient. It can involve anything from minor repairs to complete overhauls, depending on the extent of the damage.

While corrective maintenance is sometimes planned, it is often unplanned and must be carried out right away to prevent further loss or safety risks.

There are human limitations to corrective maintenance. A quick reaction helps reduce the time required for corrective maintenance.

Types of Corrective Maintenance

There are two main types of corrective maintenance: planned and unplanned.

Planned corrective maintenance is scheduled in advance, usually when a problem is found during an inspection or routine check. The team sets a time for the repair, gathers the necessary tools and parts, and prepares detailed instructions to ensure the work is completed efficiently and effectively.

Unplanned corrective maintenance occurs when a failure happens suddenly and the repair must be done immediately. This type is more common and disruptive because it is harder to predict.

Common Challenges

Corrective maintenance can be challenging for organizations that want reliable equipment. That is mainly because unplanned repairs require parts that you might not have on hand, overtime for staff, and can potentially pose safety issues.

Some organizations make the mistake of being overly reliant on corrective maintenance.

Depending on resource availability, communication between maintenance professionals can slow down the process. It can also blow a hole in your maintenance budget and cause havoc in your maintenance processes.

Root Causes of Corrective Maintenance

One approach to reduce corrective maintenance is to find the root cause of the issues.

Some common reasons why organizations overutilize corrective maintenance include:

• Overall equipment reliability
• Staff errors
• Technical ability
• Limited data and maintenance history
• Budget constraints

Corrective maintenance often results from issues that could have been avoided or reduced. Problems related to equipment reliability, planned maintenance gaps, and staff errors all play key roles.

Equipment Failure Analysis

The most common type of unexpected repair is major equipment failure.

There are several reasons why machines break down, wear out, or experience poor design or the use of substandard parts.

Aging equipment can be more prone to sudden malfunctions, causing unplanned maintenance tasks.

Companies often utilize failure analysis tools, such as Root Cause Analysis (RCA), to identify the root causes of equipment failures.

RCA investigates the specific reason for breakdowns, whether it’s physical damage, repeated stress, or problems with installation.

Lack of Preventive Maintenance

Not following a structured preventive maintenance plan increases the risk of unexpected equipment failure.

One approach commonly used is the implementation of a maintenance schedule using a Computerized Maintenance Management System (CMMS), such as WorkTrek.

A schedule alone will not be sufficient. Your maintenance program and overall maintenance strategy should include a CMMS system that can easily track these schedules and automatically generate work orders.

CMMS systems can further automate the process by sending automatic notifications and tracking all work being performed and completed.

Identify Human Errors

Humans can make mistakes that can affect equipment uptime. These errors are generally attributed to the following:

• Poor training
• Procedures are not clearly defined
• Poor communication

There are simple errors, such as using the wrong tools and forgetting a step in the process. There are other serious issues, such as not following LOTO and other safety procedures.

To reduce human errors, focus on training staff, providing clear and concise visual documentation, and ensuring that everyone prioritizes safety procedures.

A culture that encourages reporting and reviewing mistakes without blame helps teams learn from errors.

Benefits of Reducing Corrective Maintenance

By minimizing corrective maintenance, companies can enhance efficiency, improve plant operations, and help reduce emergency work for maintenance workers.

This can directly lead to more reliable and stable operation, with fewer emergencies and surprises.

Reducing corrective maintenance can also lead to more efficient use of working hours and reduced overtime.

Maintenance technicians can focus on planned tasks instead of rushing to fix equipment when it breaks.

Fewer emergencies mean less wasted time searching for tools and spare parts. Instead, repair and maintenance work follow a schedule.

Lower Maintenance Costs

High corrective maintenance rates lead to expensive urgent repairs, overtime pay, and emergency part orders.

When problems are addressed proactively, parts can be ordered in bulk at lower prices, and staff hours are managed more efficiently.

Repairing equipment after failure often causes hidden costs. Damaged machines may affect other connected parts, driving up repair bills. Reducing corrective maintenance controls these extra costs.

Improved Equipment Reliability

When machines are maintained, they tend to break down less and function more efficiently.

This helps companies improve plant performance and the overall maintenance organization performance and reliability.

Another adverse side effect of unplanned corrective maintenance is that it can reduce the equipment’s lifespan.

With fewer sudden failures, teams spot early warning signs before a major issue happens.

Developing Maintenance Schedules

One step in reducing maintenance costs is to develop a maintenance schedule that involves setting specific times for each maintenance task.

Most companies use calendars, software, or spreadsheets to plan out when their equipment needs attention.

Routine Inspections

Routine inspections are the cornerstone of identifying issues before they escalate into costly repairs.

Inspections involve checking equipment for signs of wear, damage, or failure.

Maintenance teams must be aware of what to look for during each inspection, including unusual noises, leaks, or loose parts.

Using a maintenance checklist helps make sure maintenance personnel don’t miss anything.

Lubrication and Cleaning Practices

If you are looking for the highest return on investment (ROI) on your maintenance budget, then you should focus on a proper lubrication and cleaning process.

This approach offers numerous benefits, is generally inexpensive, and is easy to perform.

Keeping moving parts greased reduces friction and heat, which lowers the chance of failure.

Follow the manufacturer’s recommendation since each machine has its own specific needs regarding the frequency and type of lubricant to use.

Make regular cleaning part of your maintenance operation.

Cleaning removes dirt, dust, and other debris that can accumulate and cause malfunctions, thereby reducing the need for emergency maintenance and improving operational efficiency.

Predictive Maintenance Techniques

Another way to reduce corrective maintenance is to implement a predictive maintenance program.

This type of maintenance is more advanced and uses a variety of IoT tools to “predict” based on algorithms when a piece of equipment is going to fail.

Some of those techniques include:

Condition Monitoring

Condition monitoring involves checking the health of machines by measuring parameters such as temperature, pressure, and noise. Sensors collect real-time data as the equipment runs.

Teams watch for any changes that could mean something is starting to fail.

For example, if a motor’s temperature continues to rise, it may require service soon. Condition monitoring can help spot hidden problems and avoid sudden breakdowns.

Vibration Analysis

Vibration analysis examines how machines move and vibrate while in operation.

All machines create some vibration, the key is to understand if a vibration is normal or excessive.

This is accomplished by using a variety of sensors that measure the frequency and strength of vibrations.

Unusual spikes or patterns can signal issues such as misalignment, loose parts, or balance problems.

Benefits of vibration analysis:

• Finds problems early, often before noise or failure occurs
• Reduces the need for emergency repairs
• Extends the life of critical equipment

Vibration analysis is typically used on large motors, pumps, and manufacturing tools.

Thermography Applications

Thermography uses infrared cameras to see temperature differences on equipment surfaces.

Using data and analytics, thermography can detect problems such as poor lubrication or electrical faults.

This can be done either manually with handheld tools or with cameras that are permanently mounted in the facility.

These thermal scans quickly spot overheating parts that might otherwise go unnoticed.

Using thermography helps reduce fire risks and prevent unexpected shutdowns. Some industries use it to check wiring, motors, and even belts for early warning signs.

Technology and Tools for Maintenance Optimization

Another effective way to reduce corrective maintenance is to implement a modern maintenance management software.

Computerized Maintenance Management Systems (CMMS)

A Computerized Maintenance Management System, like WorkTrek, is software designed to organize and streamline maintenance activities.

Implementing a CMMS enables teams to schedule preventive maintenance, track work orders, monitor inventory, and maintain detailed records of equipment and repairs.

Many companies utilize CMMS because it streamlines the planning and tracking of all maintenance tasks in one centralized location.

When an unexpected breakdown happens, teams can quickly see work history, access repair guides, and check which spare parts are available.

A CMMS can also send reminders when equipment should be checked or serviced.

This helps prevent issues from getting worse and reduces unscheduled downtime.

Data-Driven Decision Making

Collecting and analyzing maintenance data enables teams to identify patterns and make informed decisions.

Large amounts of information can be gathered from CMMS, sensors, and work reports.

Teams can track how often repairs are needed, how long machines last between failures, and which parts fail most.

With this information at hand, maintenance teams can focus on the most critical issues first, determine when equipment should be replaced, and select the most effective maintenance methods.

This is best incorporated as part of a comprehensive preventive maintenance plan.

Common Mistakes to Avoid

Overreliance on Reactive Maintenance
Many teams wait until equipment breaks and there is unplanned downtime before addressing corrective maintenance needs. This typically results in unexpected downtime and increased costs. Instead, regular checks and preventive maintenance help keep assets running smoothly.

Neglecting Preventive Tasks
Skipping scheduled maintenance can make small problems become larger ones. Don’t skip on simple tasks, such as cleaning, lubricating, and inspecting equipment.

Poor Scheduling and Planning
Not using maintenance schedules can lead to numerous problems. This means that critical checks are missed or resources are unavailable when they are most needed. Focus on creating a maintenance schedule, preferably as part of your CMMS system.

Using Incorrect or Low-Quality Parts
Cheap parts tend to break down. Don’t skip on buying the wrong part or one that is not compatible with your system. Saving a few dollars now will cost you a lot more down the road.

Table: Common Maintenance Mistakes and Effects

Conclusion

Reducing corrective maintenance takes ongoing effort. Maintenance teams should focus on both technology and training to see the best results.

Investment in the right technology helps organizations track issues, automate workflows, and keep better records. Reliable tools also make it easier to spot problems early.

Focusing on regular inspections and preventive maintenance will help catch many problems before they worsen.

Staff training is also essential. Well-trained employees are better equipped to identify and resolve problems more efficiently. They also use equipment in safer, smarter ways.