Full definition
Maintenance performed after a failure or breakdown has already occurred, with the objective of restoring the equipment to functional condition. Also called reactive, breakdown, or run-to-failure maintenance. This is the most expensive maintenance strategy because: (1) the failure often causes collateral damage to adjacent components (a failed bearing can destroy a shaft, seal, and housing), (2) unplanned downtime is 3-10x more costly than planned downtime (emergency parts at premium prices, overtime labor, expedited shipping, lost production), and (3) safety risks are higher during emergency repairs under time pressure. Studies across manufacturing industries consistently show corrective maintenance costs 5-10x more per repair event than the same repair performed proactively. However, corrective maintenance is a legitimate strategy for non-critical, low-cost, redundant equipment where the cost of prevention exceeds the cost of failure (e.g., light fixtures, non-critical pumps with installed spares). Per RCM (reliability-centered maintenance) methodology, approximately 10-20% of plant assets are appropriate for run-to-failure strategy. The goal of a mature maintenance organization is to minimize corrective maintenance to <20% of total maintenance work orders through effective preventive and predictive programs.