Corrective maintenance not only ensures that equipment and machinery operate smoothly but also helps businesses minimize production disruptions. Unlike preventive or scheduled maintenance, corrective maintenance is typically applied when a fault has already occurred. So, what is corrective maintenance? What are the steps involved in the corrective maintenance process? Let’s explore these questions with INTECH Service in this article!
What is Corrective Maintenance?
Corrective maintenance is an activity performed when equipment or machinery has malfunctioned and needs to be repaired to resume operation. This type of maintenance is reactive, meaning it is performed only after a problem has arisen. Corrective maintenance includes a range of tasks, from inspecting and replacing faulty components, repairing defects, performing regular maintenance, to redesigning or upgrading to improve equipment performance and availability.
Benefits of Corrective Maintenance
Quick Problem Fixing: Corrective maintenance helps address faults immediately, minimizing downtime, reducing production losses, and ensuring work progress.
Initial Cost Savings: This maintenance method allows for savings in initial investment costs since there is no need to invest in maintenance facilities or regular upkeep. Thus, it is commonly used in factories producing stainless steel, iron, and steel, particularly in production lines without systematic approaches.
Detection of Hidden Issues: During repairs, technicians may uncover other latent faults in the equipment, helping to prevent more significant issues in the future.
Flexibility: Corrective maintenance can be performed whenever a fault occurs, without adhering to a fixed schedule.
Drawbacks of Corrective Maintenance
Long-Term Inefficiency: Corrective maintenance only addresses immediate faults without focusing on the root cause of problems. This can lead to progressive damage over time, resulting in more significant repairs, longer downtime, and higher costs.
Higher Long-Term Costs: Although initial costs are saved, continuous repairs of malfunctioning equipment will result in higher overall maintenance costs compared to preventive maintenance.
No Assurance of Continuity: Repairs focus only on current issues and do not improve equipment reliability or prevent similar future faults.
Impact on Productivity: Downtime for repairs can disrupt production processes, reduce productivity, and affect project timelines.
Corrective Maintenance Process
The corrective maintenance process generally includes the following steps:
Step 1
Identify the Problem: Observe and use monitoring equipment to check operational metrics, unusual noises, high temperatures, fluid leaks, etc. When a fault is detected, the operating personnel or related departments should report the issue.
Step 2
Assess Severity: Evaluate the impact of the fault on the production process. Categorize the fault into different levels: emergency, critical, moderate, minor, to determine the priority of addressing it.
Step 3
Plan Maintenance: Based on the severity assessment, specify the tasks needed to address the issue. The plan may include scheduling maintenance, preparing materials, and spare parts.
Step 4
Perform Maintenance: Shut down the equipment or system with the fault. Repair or replace faulty components with new ones. Reassemble parts after repair or replacement.
Step 5
Test, Trial, and Evaluate: Conduct technical checks on the equipment’s specifications post-repair. Then, run the equipment to ensure stable operation. Finally, record the repair results, the cause of the fault, and the corrective measures taken.
Types of Corrective Maintenance
Delayed Corrective Maintenance
This type of maintenance involves addressing faults or issues not immediately after detection but scheduled for a later time. Typically, these faults do not immediately impact the production process severely.
Emergency Corrective Maintenance
This type of maintenance is performed immediately after a fault or malfunction occurs. It is applied when immediate intervention is required to prevent worsening conditions, ensure safety, or maintain equipment performance.
Planned Corrective Maintenance
This type is scheduled or planned to address specific faults or issues in machinery, equipment, or systems. It is usually planned in advance and integrated into the company’s regular maintenance schedule.
This information provides a detailed overview of corrective maintenance. With extensive experience, INTECH Service proudly stands as a leading provider of professional maintenance services, helping businesses reduce costs, increase productivity, and ensure continuous operation. Contact INTECH Service today for prompt consultation!