Ways to reduce reactive maintenance in the Indian industrial sector

Ways to reduce reactive maintenance in the Indian industrial sector

Reactive maintenance can be deemed as any kind of planned or unplanned maintenance operation which has been classified as urgent; because of the immediate requirement of attention in this regard. Industry estimates illustrate the fact that more than 50% of the Indian indigenous industries employ only medium levels of maintenance strategies whereas the highest levels of maintenance strategies being employed are unnaturally low- near about 10%. 

Problems associated with maintenance strategies in the Indian industrial sector :

Pertinent data and statistics related to maintenance in the Indian industries suggest that the companies are not intent on focussing and providing attention on the following :

  • Access to an adequate budget for the upkeep of equipment
  • Defining the role and responsibility of the maintenance personnel
  • Lack of interest in the implementation of newer techniques like RCM and TPM.

Reactive maintenance results when organisations operate traditionally and unidirectionally; thus negatively impacting morale. The productivity of the organisations stumble, workers and labourers suffer from job insecurity and finally, all of these reasons result in organisations losing a significant amount of money which might cause financial depletion of the organisation’s worth.

Actions to reduce reactive maintenance and augment proactive maintenance :

The various steps which can be taken to introduce proactive maintenance actions in industries can be enumerated below. 


  • Establishing a robust Preventive Maintenance as well as Predictive Maintenance program through the usage of formal reliability centred maintenance analysis and manuals on original equipment manufacturers, as well as relying on staff experience helps in recognition of machine defects; thus preventing the breakdown of equipment and the associated damage that results from it.
  • Establishing a reliability team helps in keeping a team of focussed individuals concentrating on asset reliability and plant availability, depending on the AMS system for failure analysis and the decisions relating to root cause analysis, FMEA and RCM as well. 
  • Performing Root Cause Analysis of the worst possible events to identify the true nature of the cause based on the origin of the events.
  • Performing a localised FMEA helps in the identification of a specific system or asset to distinguish a problem and validating its failure modes by strict comparison with failure history based on AMS.
  • The utilisation of Defect Elimination Techniques helps in augmenting the working levels and cross-functional groups.
  • Establishment of a core team to manage the entire AMS system involves building standard operational procedures, running error checks, establishing mandatory fields and choice lists; all of which help in analysing future events. 
  • Performing formal job planning helps in the provision of sequential steps, providing safety precautions to incumbent hazards and referencing of materials and permits.
  • Managing reactive work by trending and comparison of the percentage of reactive maintenance by employing structured query language and proper planning and scheduling of essential operations.
  • Capturing good failure data and assessing failure modes helps in failure analysis to identify the worst-case scenarios and reduction of failure analysis time up to a huge extent; that is, almost 90%. Improper data can result in limitations to extract meaningful reports like failure analytics. A combination of the failed component, component problem and cause code results in the development of optimum maintenance strategy while specifying the mode of failure. 


These actions, when implemented, result in the conversion of reactive maintenance operations into more proactive ones; thus executing leaner maintenance strategies and therefore improving the industrial operations by a huge extent.

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