Difference Between Downtime & Breakdown Time in Terms of Maintenance

Many people use the terms "breakdown" and "downtime" interchangeably, but there is a significant difference between these two terms. This blog will explore these differences and the implications of each on asset management. Let's begin by defining these terms.

What Is Asset Breakdown & Breakdown Time?

An asset breakdown occurs when an asset stops working due to a problem. Breakdown time is the period from when the asset fails until it is repaired and operational again. During this time, the asset is not productive, leading to potential losses in production and efficiency.

Key Points about Asset Breakdown:

• Definition: The asset is not working due to a malfunction.
• Breakdown Time: The period during which the asset is out of service.
• Impact: Loss of productivity and increased repair time and costs.

What Is Downtime?

Downtime refers to the period when assets or equipment are not operational. It can be categorized into two types: planned and unplanned.

Planned Downtime: This is scheduled downtime for activities like maintenance, upgrades, or part replacements. It is controlled and planned to minimize impact on productivity and costs.

Unplanned Downtime: This occurs unexpectedly due to equipment failure or other unforeseen issues. It is more disruptive and can lead to significant losses in productivity and increased maintenance costs.

Key Differences Between Downtime and Breakdown Time

1. Nature of Activity

• Downtime: Can be planned (scheduled maintenance) or unplanned.
• Breakdown Time: Always unplanned, occurring due to sudden asset failure.

2. Cost-Effectiveness

• Downtime: Planned downtime is cost-effective and controlled.
• Breakdown Time: Unplanned breakdowns are costly due to emergency repairs and production delays.

3. Production Impact

• Downtime: Planned downtime is scheduled to minimize production impact.
• Breakdown Time: Causes delays and interruptions in production.

4. Maintenance Types

• Downtime: Includes preventive and condition-based maintenance.
• Breakdown Time: Involves breakdown maintenance or emergency repairs.

Proactive Maintenance: The Solution to Minimize Downtime and Breakdown Time

Proactive maintenance strategies, including preventive and predictive maintenance, can significantly reduce both downtime and breakdown time.

Preventive Maintenance: Scheduled maintenance to keep assets in optimal condition and prevent failures.

Predictive Maintenance: Uses data and analytics to predict when maintenance is needed, preventing unexpected breakdowns.

According to Statista, the global predictive maintenance market is expected to reach around 23.5 billion U.S. dollars by 2024, growing at a compound annual growth rate of almost 40 percent between 2018 and 2024. This highlights the growing importance of predictive maintenance in minimizing asset downtime and breakdowns.

The Role of CMMS in Proactive Maintenance

A Computerized Maintenance Management System (CMMS) like Infizo Desk can help organizations implement proactive maintenance strategies effectively.

Benefits of CMMS:

• Scheduled Maintenance: Automates maintenance schedules to ensure timely upkeep of assets.
• Asset History: Tracks the maintenance history of each asset, helping in better decision-making.
• Reducing Downtime: Ensures regular maintenance, preventing unexpected failures.
• Minimizing Maintenance Costs: Optimizes maintenance activities, reducing overall costs.
• Effective Work Order Management: Streamlines the creation and tracking of work orders.
• Increased Productivity: Enhances operational efficiency by reducing downtime.
• Enhanced Safety: Ensures that assets are maintained in safe working conditions.
• Automated Work Management: Provides alerts and notifications for maintenance activities.

Conclusion

Understanding the difference between downtime and breakdown time is crucial for effective asset management. By implementing proactive maintenance strategies and using CMMS software, organizations can minimize both downtime and breakdown time, ensuring smoother operations and better productivity.

Frequently Asked Questions (FAQs)

What are the benefits of CMMS software?

• Scheduled maintenance
• Detailed asset history
• Reducing downtime
• Minimizing maintenance costs
• Effective work order management
• Increased productivity
• Enhanced safety
• Automated work management with alerts and notifications

How can machine downtime be decreased and uptime increased?

‍To reduce downtime, ensure that machines receive regular maintenance to keep performance levels high. Regular maintenance prevents extensive repairs and keeps assets operational, thereby increasing uptime.

What is breakdown maintenance?

‍Breakdown maintenance is performed on assets that are already in a failed state or about to fail. It can be either planned (scheduled to fix known issues) or unplanned (emergency repairs). For example, run-to-failure maintenance is a type of breakdown maintenance.

By using Infizo Desk and adopting a proactive maintenance approach, organizations can effectively manage their assets, reduce unnecessary expenses, and improve overall productivity.