For manufacturers, equipment must consistently and reliably meet delivery timelines and customer expectations.
However, machines will fail, no matter how reliable, and without the proper approach to the different types of maintenance, you may face a costly burden.
This is why understanding the various types of maintenance is essential. This is also why understanding the types of downtime is important. If you’ve experienced an unscheduled downtime, for example, this may be impacting your ability to be productive and deliver on time.
In this article, we will explain each maintenance type, when to use each type, and how specific systems, such as ManufApp, can help manufacturers minimize delays and reduce costly breakdowns.
Types of Maintenance in Manufacturing
Finding the best approach to maintenance can also help companies reduce costs, save time, and contribute to the longevity of their equipment. There are five important maintenance types to be aware of.
1. Reactive Maintenance (Run-to-Failure)
Reactive maintenance involves repairing equipment after it breaks. While this process is simple and seems inexpensive upfront, it presents a risk of unplanned downtime and higher repair costs.
Example: A conveyor motor burns out due to overheating during peak hours because it wasn’t properly monitored and subsequently broke down.
Use case: Limited to non-critical machines where downtime doesn’t matter significantly.
2. Preventive Maintenance
This method is based on a schedule. Machines or equipment are serviced or inspected at regular intervals to prevent problems from occurring before they occur.
Example: Changing the coolant and filters in a CNC machine every 100 operating hours.
Pro: Able to provide maximum uptime and diminished likelihood of emergency service or repair.
3. Predictive Maintenance
Sensors or monitoring systems continuously check condition and performance, offering alerts and information that allow technicians to intercept imminent failure.
Example: Vibration sensors on a gearbox detect imbalance, warning maintenance personnel before failure occurs.
Pro: This can avoid unnecessary maintenance while lowering the chance of downtime.
4. Condition-Based Maintenance
Condition-based maintenance relies on actual real-time data. Maintenance is performed based on real-time indicators as the temperature, pressure, and other limits are exceeded.
Example: Hydraulic oil is changed when its viscosity falls outside an unacceptable range.
Best suited for: Capital equipment that can be continuously monitored and maintained.
5. Corrective Maintenance
Corrective maintenance occurs after the failure at the fault has occurred but before a complete breakdown. It is a mid-level strategy between reactive maintenance and preventive maintenance.
Example: Replacing or fixing a worn and visible, yet still functional, damaged belt.
Aim: Decrease future risk while minimizing service workloads, including over-service work.
Different Types of Downtime in Manufacturing
All types of downtime negatively affect production, delivery, and revenue operations. Manufacturers must understand the details of every type of downtime to manage their operations effectively.
1. Planned Downtime
Planned downtime is scheduled downtime that is meant for specific maintenance or intentional tasks such as inspections, regular maintenance, machine upgrades, etc.
Example: Roughly two hours every Friday would be planned downtime so that the machines could be scheduled to be cleaned when they required it.
How to manage: Find a way to manage planned downtime when production shifts and set stages of production are complete so that you are not interrupting production.
2. Unplanned Downtime
Unplanned downtime is unannounced downtime, which is always caused by breakdowns, power outages, or human errors.
Example: A drill press would have experienced unplanned downtime if the bearings had a substantial enough amount of wear that was not detected.
Consequences: Results in delays, missed dates for deliveries, and unnecessary costs due to repair, replacement, and schedule changes.
3. Idle Time
Idle time refers to situations where the machine is readily available to operate but cannot operate due to outside circumstances. These circumstances might include waiting for materials, waiting for outside instructions, etc.
Example: The welding machine would have idle time if it were incapable of operating because raw materials were late in arrival.
Challenge: Idle time is a significant part of missing efficiencies that are usually forgotten.
4. Micro Downtime
Micro downtimes are very short durations of downtime, often occurring in regard to seconds through a few minutes, depending on the scenario. Micro downtime typically happens due to minor jams, resets, or temporary errors regarding sensors.
Example: Even if the labeling machine continues to stop for a typical interval of time, it would experience micro downtimes if the process at which it labels was interrupted due to sticker misalignment.
Important note: Micro downtimes may appear small, but they can add up quickly throughout the time of the shift.
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Track, schedule, and analyze downtime with real-time insights — all in one platform.
How ManufApp Is Helping Manufacturers Get Ahead
ManufApp adds a real-time digital layer over your shop floor activities. It helps teams identify, record, and address problems quickly—before they impact production.
With ManufApp, you can:
- Record downtime directly from a machine or operator panel.
- Establish recurring maintenance schedules for all asset types.
- Get real-time alerts for breakdowns or delays.
- Analyze downtime results by shift, machine, or department.
- Link IoT to your maintenance management for predictive and condition-based maintenance.
Instead of keeping paper logs or using Excel trackers, Manufapp delivers credible, reliable data that drives action.
Conclusion: Don’t Let Downtime Run Your Factory!
All manufacturers have downtime. What separates the best from the rest is how you deal with it. By using the right maintenance strategy and knowing your downtime patterns, you can minimize waste, maximize uptime, and prolong your machines’ life. Keeping track of all of this on paper is tough. ManufApp provides the tools you need to ease the burdens of tracking, planning, and decision-making.
Want to check it out in real time? Book a free demo and see how ManufApp helps you streamline maintenance workflows.
