Reactive Maintenance
Work performed after an asset has failed — often called break-fix or run-to-failure.
Definition
Reactive maintenance (also break-fix or run-to-failure) is maintenance performed after an asset has lost its intended function. It is the opposite of preventive and predictive maintenance.
When reactive maintenance is rational
Not every asset deserves a PM. Low-criticality, low-cost, easy-to-replace items with no safety or downstream impact are often best run to failure. The judgment is deliberate — not accidental.
Warning signs of over-reaction
- Reactive work hours > 50% of total labor
- MTTR climbing while MTBF falls
- Repeat failures on the same asset within 90 days
- PM compliance under 70%
- Overtime budget absorbing production losses
How FacilityLane classifies work
FacilityLane tags each work order as reactive, preventive, or condition-based. The ratio is a core reliability KPI. LAYLA can tell you the trend by asset, class, or site.
FAQ
Common questions about Reactive Maintenance.
No. Deliberate run-to-failure on low-consequence assets is a legitimate strategy. The problem is when reactive work dominates by accident, not by design.
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