What is Corrective Maintenance?

Corrective maintenance is the process of repairing or restoring equipment and systems after failure or when a defect has been identified. Unlike preventive maintenance, which aims to prevent failures before they occur, corrective maintenance addresses issues as they arise with the goal of restoring machinery to proper working order.

Corrective maintenance can be either planned or unplanned:

  • Planned corrective maintenance: Involves scheduling repairs after identifying critical issues during inspections or routine checks. Corrective maintenance can only be planned when a repair is not needed immediately, but will still need to be completed in a timely fashion.
  • Unplanned corrective maintenance: Occurs in response to unexpected failures, requiring immediate attention to restore functionality.

Both planned and unplanned corrective maintenance are essential for dealing with unforeseen problems and ensuring the continuous operation of equipment and systems. It plays a critical role in maintaining productivity and minimizing downtime, especially when unexpected issues arise.

When to Use Corrective Maintenance 

Identifying the need for corrective maintenance involves regular monitoring and inspections of equipment and systems. Here’s how to identify a need for corrective maintenance and when to use it:

Identification:

  • Regular inspections: Conduct routine checks and inspections to identify any signs of wear, damage, or malfunction.
  • Performance monitoring: Use sensors and monitoring tools to track equipment performance and detect abnormalities or declines in efficiency.
  • Failure reports: Analyze historical data and failure reports to identify patterns and predict potential issues.

When to Use Corrective Maintenance:

  • After failure detection: When a failure or defect is identified during routine inspections or monitoring, corrective maintenance should be initiated to address the issue.
  • Post-breakdown: If equipment fails unexpectedly, immediate corrective maintenance is required to restore functionality.
  • End-of-life components: When components reach the end of their useful life and fail, corrective maintenance ensures their timely replacement.

By identifying issues early and addressing them promptly, organizations can minimize the impact of equipment failures and maintain operational efficiency.

Types of Corrective Maintenance and Examples

Corrective maintenance can be categorized into several types based on the nature of the maintenance activities and the urgency of the repairs. Here are the main types and examples:

Deferred Corrective Maintenance

  • Definition: Repairs that are identified but scheduled for a later time when it is more convenient or when necessary resources are available.
  • Example: Replacing a worn-out part during the next planned downtime instead of immediately.

Immediate Corrective Maintenance

  • Definition: Urgent repairs that must be carried out immediately to prevent significant downtime or safety hazards.
  • Example: Fixing a broken conveyor belt that halts production.

Both types of corrective maintenance can be applied to various industries and applications. Here are some common examples:

  1. Machinery repairs: Repairing a malfunctioning CNC machine in a manufacturing plant to restore production capabilities.
  2. HVAC system fixes: Addressing a faulty air conditioning unit in an office building to ensure a comfortable working environment.
  3. Electrical system repairs: Replacing a blown fuse or repairing a damaged electrical circuit to restore power in a facility.
  4. Vehicle maintenance: Fixing a broken-down forklift in a warehouse to ensure materials can be moved efficiently.
  5. IT equipment repairs: Replacing a failed hard drive in a server to restore data access and prevent downtime.

Benefits and Disadvantages of Corrective Maintenance

Corrective maintenance can be beneficial in some scenarios, but it isn’t always the best approach to maintenance. Understanding the benefits and disadvantages of this strategy can help organizations make informed decisions about when to use corrective maintenance alongside other maintenance approaches.

Benefits of Corrective Maintenance

  • Immediate issue resolution: Corrective maintenance addresses problems as they arise, ensuring that equipment is quickly restored to working condition.
  • Reduced planning needs: Since it is performed after a failure is detected, corrective maintenance requires less upfront planning compared to preventive maintenance.
  • Cost-effectiveness for non-critical systems: Corrective maintenance can be more cost-effective than implementing comprehensive preventive maintenance programs for equipment that is not critical for production.

Disadvantages of Corrective Maintenance

  • Increased downtime: Unplanned corrective maintenance can lead to significant downtime, impacting productivity and operational efficiency.
  • Higher costs for critical failures: Unexpected failures in critical systems can result in high repair costs, emergency service fees, and potential production losses.
  • Resource allocation challenges: Immediate corrective maintenance may require rapid allocation of resources, which can disrupt planned activities and strain maintenance teams.
  • Safety risks: Sudden equipment failures can pose safety hazards to personnel and may lead to accidents or injuries.

By weighing these benefits and disadvantages, organizations can determine the appropriate balance between corrective and preventive maintenance strategies to optimize their maintenance programs.

Managing Corrective Maintenance with a CMMS

A computerized maintenance management system (CMMS) is a specialized software solution for managing corrective maintenance activities effectively.

Organizations that use a CMMS see increased efficiency, reduced machine downtime, and improved maintenance response times when unplanned breakdowns happen. A CMMS also enables comprehensive reporting and analytics, which provide valuable insights for optimizing maintenance strategies and preventing future failures.

Here are five CMMS features that can enhance corrective maintenance management:

  1. Centralized maintenance data. A CMMS centralizes all maintenance-related data, including failure reports, work orders, and equipment history, making it easy to track and manage corrective maintenance activities.
  2. Automated work order creation and management. A CMMS can automatically generate work orders when a failure is detected, ensuring prompt attention to issues. The software can also track the progress of work orders from creation to completion, providing visibility into the status of corrective maintenance tasks.
  3. Real-time monitoring and alerts. The software is designed to integrate with sensors and monitoring systems to detect equipment issues in real time. When anomalies are detected, the CMMS can send alerts and notifications to maintenance teams, enabling quick response times.
  4. Resource allocation. A CMMS helps allocate the right personnel and tools for corrective maintenance tasks, ensuring efficient use of resources. It can also track inventory levels of spare parts and materials, ensuring availability for immediate repairs.
  5. Mobile access. Most CMMS programs offer a mobile app,  allowing maintenance personnel to access work orders, equipment information, and failure data on the go, enhancing flexibility and efficiency.

By leveraging a CMMS such as eMaint for corrective maintenance, organizations can enhance their maintenance processes, ensure quick resolution of issues, and maintain high levels of operational efficiency and reliability.

To learn more about what a CMMS can do for your organization, speak with a specialist or try a free demo of eMaint today.