Introduction Reactive maintenance represents one of the most commonly employed maintenance approaches in metal manufacturing, including preventive and predictive maintenance.  In this article, we will explore in more detail what reactive maintenance is, when and why it is used, how to best perform it, its advantages and disadvantages, as well as the comparison between planned and reactive maintenance.  In addition, we will provide you with a number of real-life examples of effective reactive maintenance in metal manufacturing plants. What Is Reactive Maintenance? Unlike in prescriptive and preventive maintenance where equipment failure is addressed before it occurs, in reactive maintenance, the...

What is Mean Time to Failure (MTTF) and How to Calculate It? In a busy facility or manufacturing factory with ten thousand products handled every day, downtime can translate to significant financial losses. Equipment downtime is the period during which a machine, system, or piece of equipment is non-operational due to a failure, maintenance, repair, or other unplanned interruption.  This unproductive time can be caused by mechanical breakdowns, software malfunctions, power outages, human error, or scheduled maintenance. It is an important indicator for businesses seeking to optimize operations in food and beverage manufacturing (or other industries), reduce economic impact, and...

What Is Design Failure Mode and Effect Analysis? Imagine launching a product that customers love for its reliability and performance, only to discover hidden flaws that lead to costly recalls or damaged trust. This scenario is every engineer’s nightmare - exactly what DFMEA (Design Failure Mode and Effects Analysis) aims to prevent. In this guide, you’ll learn what DFMEA is, how it works, and why it’s a step you can’t skip in your product development process. You’ll get actionable tips followed by industry-specific examples, and we’ll break down the DFMEA process that will help you design reliable products from the...

What is Fault Tree Analysis? Trying to figure out the root cause of a system failure or problem using just your intelligence can sometimes feel like solving a complicated math problem. However, it doesn’t have to, especially if you make use of something like Fault Tree Analysis (FTA). It’s a method that’s known to identify the exact problems within your system and notify you of potential failures before they happen. In this post, you’ll learn what Fault Tree Analysis is, how it works, and why it’s incredibly important. Let’s jump right in. To put it simply, Fault Tree Analysis is...

If engineers had a crystal ball to predict every potential failure during the design or manufacturing phase, they’d be over the moon (literally, in some cases). But reality isn’t quite so magical. That’s why, in the 1960s, NASA came up with a game-changing methodology: FMEA (Failure Mode and Effects Analysis). Why? Because when you're building spacecraft, there’s no room for error. A single failure could mean catastrophic consequences. FMEA was their way of identifying potential problems before they happened, ensuring every system was fail-proof. Fast forward to today, FMEA has evolved into two main areas: DFMEA (Design Failure Mode and...

Effective management of maintenance, repair, and operations (MRO) inventory is critical for an organization's smooth operation. By doing so, organizations can guarantee that they have sufficient inventory readily available to prevent unscheduled downtime and avoid holding excessive inventory levels. Today we will discuss various MRO inventory optimization strategies such as Just-in-Time (JIT) and Vendor Managed Inventory (VMI) and when each approach is appropriate. Finally, we will examine how a robust computerized maintenance management system (CMMS) can effectively implement either strategy and the numerous advantages offered by a top-notch platform like LLumin's CMMS+. What is MRO Inventory Optimization? MRO inventory management...

Preventive maintenance increases overall equipment effectiveness by up to 20% and reduces maintenance costs by 10 to 40%, according to research by McKinsey & Company. [1] However, is preventive maintenance effective for an automotive facility?  A multinational company in the automotive industry created and implemented a model for the management of spare parts linked to the maintenance of existing equipment and achieved an OEE of more than 90%, according to this case study on Research Gate. [2] In 2024, there is no doubt that automotive companies need a proper maintenance plan for their equipment to function properly. Without a proper...

Imagine if just a small daily routine could save you thousands of dollars in unexpected repairs and downtime.  According to a study by Deloitte, implementing a predictive maintenance program can reduce maintenance costs by up to 40% and increase productivity, with a 70% reduction in downtime. [1] But the first step is to devote a portion of your time and create a daily maintenance facility checklist. This will give you a starting point and advantage right from the start, so implementing different types of maintenance is easy.  Don’t worry, we’ll walk you through the exact steps you need to create...

When it comes to running a facility smoothly, maintaining your equipment is a necessity. Many people fall into the trap of postponing equipment maintenance and thinking nothing will break, until it’s too late. Then, they have to worry about emergency repairs instead of predictive maintenance, which is less time-consuming and cheaper. Don’t even get us started on how much money you lose daily when you’re not using your machines.  In fact, a recent study reveals that 91% of businesses that use predictive maintenance reduce repair time and unplanned downtime. [1] And predictive maintenance is only one type of equipment maintenance....