What is Reactive Maintenance?

Reactive maintenance, also known as breakdown or run-to-failure maintenance, is the process of repairing equipment only after it has failed. This type of maintenance is often contrasted with preventive maintenance, which involves regular inspections and servicing to prevent unexpected breakdowns. The primary focus of reactive maintenance is to restore the functionality of an asset as quickly and efficiently as possible after a failure has occurred. This approach is often seen in industries where the cost of downtime is less significant compared to the upfront cost of preventive measures.

The reactive maintenance process typically includes identifying the failure, diagnosing the root cause, carrying out the necessary repairs, and verifying that the equipment is back in working order. Examples of reactive maintenance can be found in various settings, such as replacing a blown fuse in a vehicle, fixing a broken conveyor belt in a production line, or repairing an HVAC system after it has malfunctioned. While reactive maintenance can be cost-effective in the short term, it carries risks of unplanned downtime and potential inefficiencies. Comparing reactive maintenance vs preventive maintenance, it is essential to consider the operational context and the criticality of the equipment involved to determine the most suitable strategy.