Reactive Maintenance

The data below illustrates the level of reactive maintenance performed by IndustryWeek’s Best Plants winners and finalists over the past five years. How does your organization compare?

The data is the percent (%) of reactive maintenance work, in response to unexpected machine or equipment breakdown:

2007
Median = 17.3
Average = 23.2
Minimum = 0.8
Maximum = 75.5

2008
Median = 6.5
Average = 18.1
Minimum = 0.8
Maximum = 70.0

2009
Median = 15.0
Average = 25.9
Minimum = 0.8
Maximum = 80.0

2010
Median = 33.0
Average = 27.8
Minimum = 2.0
Maximum = 70.0

2011
Median = 23.9
Average = 24.6
Minimum = 1.4
Maximum = 75.0

The newsletter reminds us the “reactive” typically is not a good word when it comes to maintenance. A large percentage of reactive maintenance implies that you are not taking care of your equipment, either deliberately or otherwise. Or, it suggests that your means of taking care of the equipment is not effective.

The data shows these Best Plants winners and finalists typically have low rates of reactive maintenance. Over the past five years, their average percentage of reactive maintenance work is 23.8%.