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Here’s a scenario: You’re knee-deep in a critical project, and suddenly, a crucial piece of equipment decides to quit on you. No warning, no farewell note, just an abrupt shutdown. Chaos ensues. Deadlines are missed. Costs pile up.
Sound familiar? That, right there, is unplanned maintenance in action.
Unplanned maintenance refers to any repair or servicing that happens unexpectedly due to an unforeseen equipment failure. Unlike planned maintenance, which follows a schedule, unplanned maintenance disrupts operations, costs money, and can even compromise safety.
But here’s the thing – it’s not always avoidable.
In this blog, we’ll dive deep into what unplanned maintenance is, why it’s a costly affair, and how you can get ahead of it before it wreaks havoc on your operations. Let’s get started!
Tired of Surprise Breakdowns? FieldEx gives you the power to prevent failures before they happen. From automated PM schedules to real-time work order tracking, we help you ditch the chaos of reactive maintenance. Want to see FieldEx in action? Book a free demo today, or reach out with any questions you may have. We’re here to help.
Unplanned maintenance is any unscheduled repair or servicing that occurs due to an unexpected equipment failure. It’s usually reactive, meaning you don’t address the issue until something actually breaks down.
Unplanned maintenance isn’t just inconvenient; it’s expensive. Here’s why:
When critical equipment fails, your entire workflow can grind to a halt.
In industries like manufacturing, logistics and construction, downtime can cost thousands per hour. According to a study by Aberdeen Group, unplanned downtime costs industrial manufacturers an average of $260,000 per hour.
Sudden failures can lead to workplace hazards. For example, an HVAC failure in a food storage facility can lead to spoiled inventory, while electrical malfunctions in a factory can cause fires.
Non-compliance with industry regulations can also result in hefty fines.
Constant emergency repairs put excessive strain on machinery, leading to premature wear and tear. A study by Deloitte found that poor maintenance practices can reduce an asset’s lifespan by up to 30%.
Not all unplanned maintenance is created equal. Here are the main types:
While planned maintenance is the gold standard, some unplanned maintenance is strategic:
The key to reducing unplanned maintenance isn’t eliminating it completely; it’s about controlling and minimizing its impact. Here’s how:
If unplanned maintenance is eating away at your productivity and profits, a CMMS can help you get back in control.
Unplanned maintenance might be inevitable, but it doesn’t have to control your operations. By implementing preventive strategies and using the right tools – like FieldEx’s CMMS – you can reduce costly downtime, extend equipment lifespan and improve operational efficiency.
FieldEx gives you the power to prevent failures before they happen. From automated PM schedules to real-time work order tracking, we help you ditch the chaos of reactive maintenance. Want to see FieldEx in action? Book a free demo today, or reach out with any questions you may have. We’re here to help.
Unplanned maintenance refers to any repair or servicing that happens unexpectedly, usually due to sudden equipment failure or a breakdown you didn’t see coming.
Reactive maintenance is a type of unplanned maintenance. All reactive work is unplanned, but not all unplanned tasks are reactive; some may be chosen strategically (like run-to-failure).
Common causes include poor preventive practices, operator error, sudden equipment failure, power surges, wear and tear, or lack of spare parts on hand.
Not necessarily. In some cases – like with low-priority assets or cheap components – letting something run to failure can be more cost-effective than preventive care.
Industries with heavy equipment or critical uptime (such as manufacturing, construction, logistics and healthcare) are especially vulnerable to costly downtime.
It varies, but studies show it can cost thousands per hour in lost productivity, safety risks, and emergency labor, especially in large industrial settings.
Start with preventive and predictive maintenance strategies, track asset history, stock critical spare parts, and use a CMMS to manage it all efficiently.
Absolutely. A CMMS automates schedules, tracks equipment data, and sends alerts when assets need attention, helping you fix things before they break.
Emergency maintenance is urgent and unplanned, done to prevent immediate damage. Corrective maintenance is also unplanned but typically less urgent and done before a small issue gets worse.
If you’re always scrambling to fix things last-minute, frequently dealing with breakdowns or struggling to meet SLAs, chances are your unplanned maintenance is out of control.
Yes, a good CMMS (Computerized Maintenance Management System) can help you stay ahead of breakdowns by tracking assets, automating schedules and flagging issues early. FieldEx does all that – and more – in ONE easy-to-use platform.
If your current system is a mix of spreadsheets, emails and guesswork, it's time for something smarter.
FieldEx helps you centralize work orders, track job progress and get real-time updates across your team.
A CMMS like FieldEx automatically logs every repair, service and inspection. This means you can see patterns, plan replacements and stop fixing the same thing over and over.
Easy! Just schedule a free demo, and see how FieldEx helps you reduce downtime, automate maintenance and stay in control, without drowning in admin.
Got questions? Just get in touch! We’re here to help.
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