Reactive maintenance is a major drain on efficiency, running time, and costs. You probably know this, but what are you doing to avoid it?
And, how much reactive maintenance are you actually performing as opposed to companies that are in the top-quartile for performing the least reactive maintenance?
By moving to more preventive, predictive, and conditions-based maintenance, you can
For example, in 2010 the US Department of Energy claimed that returns of conditions-based maintenance included 10x return on investment; 25-35% reduction in maintenance costs; 70-75% reduction in breakdowns; 35-45% reduction in downtime; and a 20-25% increase in production. Sounds pretty good, no? Or how about this Jones Lang LaSalle report showing that not only does an investment in preventive maintenance pay for itself, but that in fact it results in an average 545% return on investment (wow!).
How much reactive maintenance should you be performing? Our friends at the University of Tennessee's Reliability & Maintainability Center (RMC) suggest 10%, plus or mine 5% either way. That amount of reactive maintenance would put your organization in what they refer to as the "top quartile" when it comes to reactive maintenance activity. Likewise, they recommend your organization's preventive maintenance rate be about 70% if you want to hit that same top quartile.
In this article, we'll give you a convincing list of just SOME of the reasons why your organization should reduce the amount of reactive maintenance you perform (and yes, we think our maintenance training solutions may help you reach this goal of reduced reactive maintenance).
Convergence Training are industrial training experts with a strong core of training courses related to maintenance, maintainability, reliability, and other industrial training needs.
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Want to benchmark the amount of reactive maintenance your organization performs? Quoting data from our friends at the University of Tennessee's Reliability and Maintainability Center again, in the US the top quartile is performing about 9% reactive maintenance; the average organization is at about 31% reactive maintenance; and the bottom quartile is at about 62% reactive maintenance.
How much reactive maintenance does your organization perform? What do you stand on this benchmark?
No matter the answer, here are some reasons to reduce your reactive maintenance rate even more.
See Twenty Reasons to Stop Firefighting by Dr. Klaus Blache in Efficient Plant magazine, the source of these figures, for more on this.