Study on Breakdown Maintenance and Its Impact on Industrial Productivity

Breakdown Maintenance (BM), also known as corrective or run-to-failure maintenance, is a reactive strategy performed only after equipment failure. This study presents a refined analysis of the direct and indirect effects of BM on industrial productivity. A systematic review of published literature and industrial reports was conducted to evaluate the influence of BM on key performance indicators such as downtime, repair cost, equipment life, safety, and Overall Equipment Effectiveness (OEE). Findings reveal that BM leads to substantial unplanned downtime, higher emergency repair expenses, quality losses, and accelerated asset deterioration. Indirect consequences include supply chain disturbances, reduced workforce efficiency, and increased operational risks. Although BM can be justified for non-critical, low-cost assets with minimal failure impact, its widespread use significantly reduces operational stability and long-term profitability. The study highlights the need for industries to transition toward proactive strategies such as Preventive and Predictive Maintenance to enhance reliability, reduce lifecycle costs, and ensure sustainable productivity.