Reactive maintenance costs companies thousands more than the costs of making repairs as they are needed. Companies that have not taken advantage of proactive maintenance face costs equal to the squared cost of making original repairs, but today's companies face added pressure to reduce capital spending, operate within pattern margins, and produce more results. Facilities Managers also face the struggle of unavoidable reactive maintenance, and while reactive maintenance cuts into the bottom line, Facilities Managers must understand how to handle it properly. even the best-laid plans for proactive maintenance are susceptible to problems in existing assets that may not have been well-maintained.
Reactive Maintenance Dramatically Increases Costs, But It Could Be Unavoidable
This is most commonly seen in facilities management departments implementing proactive maintenance programs for the first time. Since a proactive maintenance program has not been in place, initial implementation may lead to the identification of numerous potential faults that could contribute to asset failure. In a sense, initial findings and maintenance needs when implementing a proactive maintenance plan are technically reactive maintenance needs. Although the needs have not resulted in system failure, the likelihood of failure increases with each passing day.
Facilities Managers Need to Know How to Successfully Manage Inevitable Reactive Maintenance
Even Facilities Managers that have implemented robust preventative, proactive maintenance programs may still be subject to unforeseen circumstances, such as natural and man-made disasters. As a result, it is impractical to devote the entire maintenance budget to proactive maintenance. In other words, Facilities Managers need to know how to plan for reactive maintenance, including accounting for scheduling changes to handle reactionary maintenance needs, costs incurred, and minimize disruptions to employee productivity and guest experiences.
Steps to Plan for Reactive Maintenance When Creating a Proactive Maintenance Program
- Establish clear maintenance goals.
- Create a reliability team.
- Perform a failure mode and effects analysis.
- Prioritize items in the maintenance backlog.
- Allocate spending between proactive and reactive maintenance.
- Use technology to monitor and reduce reactive maintenance.
- Identify channels for completing work orders.
- Ensure maintenance needs are completed, and pay vendors accordingly.
- Create a backup plan for asset failures.
- Build your work schedule with proactive and reactive maintenance in mind.
- Perform a cost analysis of maintenance.
- Compile information for presentation to stakeholders.
- Continue to develop your proactive maintenance program.