{"id":14212,"date":"2023-09-05T12:16:04","date_gmt":"2023-09-05T18:16:04","guid":{"rendered":"https:\/\/limblecmms.com\/?page_id=14212"},"modified":"2025-03-12T11:12:47","modified_gmt":"2025-03-12T17:12:47","slug":"unplanned-maintenance","status":"publish","type":"page","link":"https:\/\/limblecmms.com\/learn\/definitions\/unplanned-maintenance\/","title":{"rendered":"Unplanned Maintenance"},"content":{"rendered":"

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Unplanned Maintenance<\/h1>

Everything you ever needed to know about unplanned maintenance.<\/h2><\/header>Free CMMS Buyer's Guide<\/span><\/a>\n
\n \n <\/span>Last updated on March 12, 2025<\/span>\n <\/span>\n bBrinton<\/span>\n <\/span>\n <\/div>\n\n [\/vc_column][\/vc_row][vc_row kd_background_image_position=”vc_row-bg-position-top” css=”.vc_custom_1687442797424{margin-top: 40px !important;}” el_class=”limble-page-blog-width”][vc_column][vc_column_text]<\/p>\n

What is unplanned maintenance?<\/h2>\n

The dictionary defines unplanned as something unexpected or unintentional, with related words including abrupt, spontaneous, and unannounced. When used within maintenance, it refers to an unexpected issue occurring with no forewarning and, therefore, no ability to moderate the outcome. No tasks will exist in the maintenance plan that might have averted the event, and it\u2019s unlikely that spares provisioning has been considered unless through a lucky coincidence.<\/span>[\/vc_column_text][\/vc_column][\/vc_row][vc_row kd_background_image_position=”vc_row-bg-position-top” css=”.vc_custom_1687442797424{margin-top: 40px !important;}” el_class=”limble-page-blog-width”][vc_column][vc_column_text]<\/p>\n

Table of Contents<\/span><\/h2>\n

Is unplanned maintenance the same as unscheduled maintenance?<\/span><\/a>
\nThree forms of unplanned maintenance<\/a>
\nIs unplanned maintenance bad?<\/a>
\nHow a CMMS can assist with unplanned maintenance<\/a>
\nPlanning for the unplanned<\/a>[\/vc_column_text][\/vc_column][\/vc_row][vc_row kd_background_image_position=”vc_row-bg-position-top” css=”.vc_custom_1687440273251{margin-top: 40px !important;}” el_class=”limble-page-blog-width”][vc_column][vc_column_text]<\/p>\n

Is unplanned maintenance the same as unscheduled maintenance?<\/h2>\n

No, it\u2019s a different concept. When a maintenance task is called unscheduled, it refers to a task that exists in the maintenance plan but is not scheduled for acquittal at that particular time. So the task is planned but not called for completion, making any immediate acquittal \u201cout of schedule.\u201d Unscheduled maintenance is often carried out for convenience.\u00a0<\/span><\/p>\n

A simple example might be a task to measure a brake disc to ensure it\u2019s above a minimum thickness. If you need to carry out <\/span>corrective maintenance<\/span><\/a> on a brake caliper due to a leaking hydraulic seal, it makes no sense to repair just the seal. While you have the brake assembly dismantled, you might as well carry out any other allied tasks in that area that might be due shortly.\u00a0<\/span><\/p>\n

This tactic avoids another unnecessary dismantling of the caliper in a week or two\u2019s time, saving time and money. Carrying out the disc measurement task at this time would be unscheduled maintenance.<\/span>[\/vc_column_text][\/vc_column][\/vc_row][vc_row content_placement=”middle” kd_background_image_position=”vc_row-bg-position-bottom” kd_top_separator_style=”skew-left” kd_top_separator_height=”separator-height-small” kd_bottom_separator_style=”skew-left” kd_bottom_separator_height=”separator-height-small” kd_top_separator=”true” kd_bottom_separator=”true” css=”.vc_custom_1682969576554{margin-bottom: 40px !important;padding-top: 120px !important;padding-right: 40px !important;padding-bottom: 50px !important;padding-left: 40px !important;background: #dde4e8 url(https:\/\/limblecmms.com\/wp-content\/uploads\/cta-laired-hex-4.webp?id=9077) !important;background-position: center !important;background-repeat: no-repeat !important;background-size: cover !important;border-radius: 0px !important;}” css_tablet_landscape=”.vc_custom_1682969576554{padding-bottom: 80px !important;}” css_tablet_portrait=”.vc_custom_1682969576555{padding-bottom: 80px !important;}” css_mobile=”.vc_custom_1682969576555{padding-bottom: 80px !important;}”][vc_column][vc_row_inner kd_background_image_position=”vc_row-bg-position-top”][vc_column_inner]

Checklist for Creating a Preventive Maintenance Plan<\/h2>
Following a consistent Preventive Maintenance Plan can make life easier. Use this checklist to create your own!<\/h6><\/header>[\/vc_column_inner][\/vc_row_inner][vc_row_inner content_placement=”top” kd_background_image_position=”vc_row-bg-position-top”][vc_column_inner width=”1\/2″ css=”.vc_custom_1631866454223{padding-right: 50px !important;padding-left: 0px !important;}” offset=”vc_col-lg-6 vc_col-md-12 vc_col-xs-12″ css_tablet_landscape=”.vc_custom_1631866454223{padding-right: 0px !important;}” css_tablet_portrait=”.vc_custom_1631866454223{padding-right: 0px !important;}” css_mobile=”.vc_custom_1631866454224{padding-right: 15px !important;}”][vc_raw_html]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[\/vc_raw_html][\/vc_column_inner][vc_column_inner width=”1\/2″][vc_single_image source=”external_link” alignment=”center” css_animation=”fadeIn” custom_src=”https:\/\/3975608.fs1.hubspotusercontent-na1.net\/hubfs\/3975608\/Content%20Downloads\/PM%20Checklist%20mockup.png”][\/vc_column_inner][\/vc_row_inner][\/vc_column][\/vc_row][vc_row kd_background_image_position=”vc_row-bg-position-top” css=”.vc_custom_1687440273251{margin-top: 40px !important;}” el_class=”limble-page-blog-width”][vc_column][vc_column_text]<\/p>\n

Three forms of unplanned maintenance<\/h2>\n

<\/p>\n

The three forms of unplanned maintenance refer to the extent or severity of the issue needing rectification.<\/span><\/p>\n

Reactive maintenance<\/span><\/h3>\n

Reactive maintenance<\/span><\/a> occurs when an item has ceased working. Something has unexpectedly broken down, and the maintenance technicians must pause their other commitments to return the item to service.<\/span><\/p>\n

An example of reactive maintenance might be cartons on a conveyor becoming jammed, breaking a sensor, and damaging a guide rail. The conveyor is out of operation until rectified, requiring expensive manual workarounds to run the production line. The guide rail requires welding and straightening, and stores must purchase a new sensor.<\/span><\/p>\n

Corrective maintenance<\/span><\/h3>\n

Corrective maintenance<\/span><\/a> refers to work carried out to restore an item of equipment to optimum operation. The item is functioning but may be slowing an operation, using more energy than normal, or producing a higher rate of non-conforming product.<\/span><\/p>\n

If we stay with our conveyor example, you may require corrective maintenance on a conveyor roller that appears to be seizing up. Cartons are coming down the conveyor but stopping when they reach the tight roller. It takes a second carton to knock the first forward to continue its journey, while the second carton stops and waits for a third to move it on. The roller will need to be removed and have its bearings changed or a new roller fitted.<\/span><\/p>\n

Opportunistic maintenance<\/span><\/h3>\n

Opportunistic maintenance occurs when a defect is discovered while other work is being carried out. The opportunity is taken to effect a repair while the equipment is stopped and resources are available, preventing the need for a further planned or unplanned stoppage.<\/span><\/p>\n

An example might be a machine that is stopped for cleaning when it is noticed that a machinery cover has been chafing on a stainless hydraulic line, causing wear and a reduced wall thickness. It\u2019s easier to replace the line or install a suitably-rated flex line while the machine is down than suffer a broken hydraulic tube and possible safety and environmental incidents in the future.<\/span>[\/vc_column_text][\/vc_column][\/vc_row][vc_row kd_background_image_position=”vc_row-bg-position-top” css=”.vc_custom_1687440273251{margin-top: 40px !important;}” el_class=”limble-page-blog-width”][vc_column][vc_column_text css=””]<\/p>\n

Is unplanned maintenance bad?<\/h2>\n

Not necessarily. Unplanned maintenance is an inevitable consequence of equipment operation. It\u2019s impossible to second-guess every eventuality, hold every conceivable spare, and create just-in-case tasks. Even if you were to get it right, such a plan\u2019s cost and administrative burden would cripple your organization.<\/span><\/p>\n

Maintenance spending is always planned on a risk-weighted basis. Your challenge is to identify the equipment critical to your operation, safety, or regulatory compliance, understand the myriad ways each item might fail, and target your attention and maintenance spend there.\u00a0<\/span><\/p>\n

Many items can fail without impacting safety or regulatory compliance. While there may be a cost impact to the business from the failure, does the cost of regularly carrying out maintenance outweigh the cost of the occasional unplanned failure? The following criteria provide a useful guide on whether you should consider adding the item to your maintenance plan or not:<\/span><\/p>\n