The 9 Pitfalls of Reactive Maintenance Strategies

In our previous blog From Reactive to Predictive: Smart Asset Management with GeoPal we note that poor maintenance strategies have been reported to reduce productive capacity from between 5% to 20% yearly (McKinsey). This is because organisations employing reactive strategies essentially treat the symptom of the problem rather than the root cause. Some of the common pitfalls of reactive maintenance include:

  1. Decreased Life Expectancy of Assets: Faster asset deterioration due to fix/break models.
  2. Safety Issues: Time pressures associated with reactive repairs cause increased risk taking
  3. Unplanned Expenditure: Unpredictable failure causes financial budgeting difficulties.
  4. Reduced Efficiency: Unscheduled repairs consumption leads to disruption and delay.
  5. Unpanned Asset Downtime: Assets are ‘offline’ for uncertain or lengthy periods.
  6. Reduced Productivity: Waiting times for spare parts delivery and permit approvals.
  7. Collateral Damage: Minor issues can quickly escalate into total system failures.
  8. Repeat Issues: Temporary repairs and ‘symptom management’ lead to repeat issues.
  9. Increased Energy Costs: Damaged assets often have higher energy consumption.

Avoid business disruption associated with reactive maintenance by keeping assets up and running, using IoT sensor data to predict equipment malfunctions and plan maintenance schedules. Transitioning from reactive to predictive maintenance strategies ensures organisations are prepared for Industry 4.0, transforming operations, lowering the cost of production and ultimately, improving profitability.

GeoPal's IoT-enabled mobility platform and intelligent job dispatch allows organisations with assets in the field to eliminate costly, reactive maintenance, leading a shift towards a predictive model of maintenance. With IoT sensors on assets, alarms are raised when failures occur - before it’s too late. These alarms can automatically trigger work orders that are sent to field technicians' mobile devices, maximizing asset uptime.

Advantages of Predictive Maintenance Include:

●      Increasing asset uptime

●      Reduced repair costs

●      Reduction of unscheduled repairs

●      Increased efficiency, productivity and quality

●      Extended asset lifespan

●      Increased worker utilization

●      Stable operations

With GeoPal, once an IoT device is connected, the potential to not only send and/or receive information, but to implement responsive processes, quickly delivers results – driving real business value. Transitioning from a reactive to a predictive model significantly improves key metrics such productivity, efficiency, and ultimately – profitability.

 Learn how GeoPal can help you implement a predictive maintenance strategy, request a free demo.

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