Maintenance is a critical part of keeping industrial equipment, machinery, and facilities running efficiently. Two common maintenance strategies, corrective maintenance and breakdown maintenance, are often confused with each other, but they have distinct purposes. Understanding the differences between these two can help businesses minimize downtime, reduce costs, and improve operational efficiency.
➥ What is Corrective Maintenance?
Corrective maintenance is a proactive approach to fixing issues before they turn into major failures. When a problem is detected, such as a machine making unusual noises or showing early signs of wear, it is repaired before it completely breaks down. This type of maintenance is often planned and scheduled based on regular inspections and monitoring.
➲ Examples of Corrective Maintenance:
- A technician notices a small oil leak in a machine and repairs it before it causes major damage.
- A conveyor belt with minor cracks is replaced before it snaps.
- A pump showing reduced efficiency is repaired before it stops working completely.
👉 Predictive vs. Preventive Maintenance: Which One Saves More?
➲ Benefits of Corrective Maintenance:
✅ Prevents unexpected breakdowns – Major failures are avoided by fixing small issues early.
✅ Extends equipment lifespan – Regular corrections reduce long-term wear and tear.
✅ Reduces repair costs – Fixing minor problems is cheaper than dealing with full breakdowns.
✅ Improves workplace safety – Preventing sudden failures reduces the risk of accidents.
➥ What is Breakdown Maintenance?
Breakdown maintenance, also called run-to-failure maintenance, is a reactive approach where repairs are only done after a piece of equipment stops working. In this strategy, no preventive action is taken, and machinery is allowed to run until it completely fails.
➲ Examples of Breakdown Maintenance
- A factory waits for a light bulb to burn out before replacing it.
- A cooling fan motor is only repaired after it completely stops working.
- A forklift is sent for repairs only when it breaks down in the middle of an operation.
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➲ Benefits of Breakdown Maintenance:
✅ Simple to implement – No need for scheduled inspections or monitoring.
✅ Works for non-essential equipment – Some assets can be allowed to fail without major consequences.
✅ No unnecessary repairs – If a part is still functioning, it is used to its full potential before replacement.
However, breakdown maintenance also has major risks, such as unplanned downtime, high repair costs, and potential safety hazards.
➥ Key Differences Between Corrective and Breakdown Maintenance
➥ Which Maintenance Strategy is Better?
The choice between corrective maintenance and breakdown maintenance depends on the type of equipment and business priorities.
🔹 Use Corrective Maintenance for:
- Critical machinery – If a failure would cause major downtime or safety risks.
- High-value equipment – Repairs are cheaper when done early.
- Industries like manufacturing, healthcare, and transportation, where reliability is key.
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🔹 Use Breakdown Maintenance for:
- Non-essential equipment – Items like light bulbs or air conditioners can be replaced after they fail.
- Low-cost repairs – If replacing a part is cheap and doesn’t disrupt operations.
- Industries like retail or small offices, where downtime is less critical.
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