Types of Maintenance: Reactive, Preventive, Predictive, and Condition-Based

Introduction

Choosing the right maintenance strategy can make a significant difference in your facility’s performance and costs. There is no one-size-fits-all strategy. Rather, each organization must achieve the right balance between different types of maintenance based on the nature of its assets and objectives.

In this guide, we will explore the four main types of maintenance, explain when to use each one, and how to choose the most suitable approach for your equipment.

1. Reactive Maintenance (Run-to-Failure)

Reactive maintenance, also known as run-to-failure maintenance, is the oldest and simplest maintenance strategy. Simply put, you wait until the equipment breaks down, then fix it.

When to Use Reactive Maintenance

Reactive maintenance is best suited for non-critical assets that do not affect production, inexpensive equipment that is easy to replace, devices that pose no safety risk when they fail, and aging equipment nearing the end of its useful life.

Advantages of Reactive Maintenance

This approach requires no advance planning and has low initial costs. It is particularly suitable for non-critical equipment where downtime has minimal impact on operations.

Disadvantages of Reactive Maintenance

The drawbacks include unplanned downtime that affects production, higher repair costs due to emergency repairs, potential damage to adjacent components, and difficulty planning resources and workforce.

2. Preventive Maintenance

Preventive maintenance is a proactive approach that involves performing scheduled maintenance at regular intervals to prevent breakdowns before they occur. It relies on specific time schedules or operating hours.

Types of Preventive Maintenance

Time-based maintenance involves performing tasks at set intervals, such as changing oil every three months. Usage-based maintenance is performed after a certain number of operating hours, such as maintenance every 5,000 hours. Event-based maintenance occurs after specific events, such as inspection after every 1,000 production cycles.

Advantages of Preventive Maintenance

This approach significantly reduces unexpected breakdowns and extends equipment lifespan by 20 to 40 percent. It allows for better planning of resources and budget, improves workplace safety, and saves 30 to 40 percent of maintenance costs in the long term.

Disadvantages of Preventive Maintenance

Preventive maintenance may lead to over-maintenance of some equipment, requires careful planning and organization, and has higher initial costs than reactive maintenance.

3. Predictive Maintenance 

Predictive maintenance uses data and advanced analytics to predict when equipment will fail before it happens. It relies on sensors that monitor equipment condition in real-time.

Predictive Maintenance Technologies

Vibration analysis is used for detecting bearing and balance problems. Thermal imaging helps detect abnormal temperature increases. Oil analysis reveals wear and contamination. Ultrasonic testing identifies leaks and electrical problems.

Advantages of Predictive Maintenance

Maintenance is performed only when needed and at the right time. This approach reduces unplanned downtime by up to 60 percent, improves spare parts usage efficiency, and provides deeper insight into equipment condition.

Disadvantages of Predictive Maintenance

The challenges include high initial investment costs for sensors and software, the need for specialized technical expertise, and the fact that it is not suitable for all types of equipment.

4. Condition-Based Maintenance 

Condition-based maintenance relies on continuous monitoring of specific indicators in equipment. Maintenance is performed when these indicators exceed certain thresholds.

The Difference Between Predictive and Condition-Based Maintenance

Condition-based maintenance reacts to current data, while predictive maintenance uses artificial intelligence and machine learning to predict the future.

How to Choose the Right Maintenance Strategy

There is no one-size-fits-all approach. Maintenance experts recommend allocating approximately 80 percent of your efforts to planned maintenance, which includes preventive and predictive approaches, while reserving about 20 percent for reactive maintenance on non-critical assets.

When choosing a strategy, consider the importance of the asset to production and safety, the downtime cost versus preventive maintenance cost, the availability of spare parts and ease of repair, and your budget and technical capabilities.

Conclusion

The best maintenance programs combine multiple strategies, applying each strategy to the assets best suited for it. Start by evaluating your critical assets, apply preventive maintenance to the most important ones, then gradually move toward predictive maintenance for your most critical assets.