There seems to be a bit of confusion at our plant regarding the appropriate times for creating a breakdown work order versus a corrective repair work order. From what I understand, a corrective repair order should be issued when a possible breakdown is identified during preventative maintenance or predictive maintenance, and it is addressed before any functional failure occurs. On the other hand, a breakdown work order is created after a functional failure has occurred. Feel free to correct me if I'm mistaken.
In our plant, we do not distinguish between maintenance order codes for breakdowns and corrective actions; both are categorized as corrective maintenance. Nevertheless, I concur with your viewpoint. Should we opt to differentiate these orders, breakdown orders would pertain to instances where equipment cannot remain operational until repairs are carried out.
Maintenance work can be conducted in different ways depending on the situation. The first option is preventive maintenance, which involves performing tasks before any potential failure occurs. The second option is predictive maintenance (PdM), which is done after degradation has started but before the item fails to meet its specified output. If PdM readings indicate that repair is needed, corrective maintenance is then carried out. The third option is to detect hidden failures, with replacement action taken if an item is found to be failed. Finally, if an item has completely broken down, some organizations refer to this as breakdown maintenance, while others call it corrective maintenance. It is important for all team members to be clear on the terminology used within the organization.
In the event of equipment failure, users are requested to document the start date and time of the breakdown in the Maintenance Notification or Request. Despite this, the order is still considered Corrective Maintenance.
Thank you, Vee and Eugene, for sharing your insights. I fully agree with your perspectives on PM work orders, which we primarily use for conducting inspections. Upon identifying a fault, we proceed to create a corrective repair work order. This method enables us to track the effectiveness of our maintenance program, distinguishing between CR work orders and BR work orders. It is essential to have proper definitions in place in order to accurately measure our performance. Eugene, I appreciate your suggestion regarding Breakdown reports, and we are actively working on incorporating this into our procedures. In the event of a breakdown, our technicians (millwrights or electricians) fill out a simple breakdown form that includes details such as the date and time of the breakdown, location, time taken to fix (MTTR), description of the issue, and countermeasure implemented. It's crucial to document not only breakdowns but also corrective actions for further analysis and improvement. Your feedback is highly valuable. Thank you - Mike.
Our Computerized Maintenance Management System (CMMS) automatically logs the start of a breakdown reported by the requester in a maintenance notification. This information is then linked to the date and time of the corrective order to determine the turnaround time for repairs. The equipment number, description of the issue, and location are all captured in the notification, allowing maintenance technicians to quickly assess the situation. Any additional comments or clarifications provided by the technician during the corrective order process help to confirm or adjust the initial problem description. The corrective tasks implemented by maintenance to address the issue are considered as part of the overall countermeasure.
You're absolutely right, and I appreciate your clarification. It's extremely important to discern the difference between the two - it comes down to proactive vs. reactive to repair procedures. A breakdown work order is reactive, as it's issued once a failure has occurred. In contrast, a corrective repair order is proactive; it's issued to prevent the failure. This not only prevents disruptions in the workflow but can also extend the equipment’s lifespan, making it a more efficient solution in the long run.
You're spot on in your understanding! To add a bit more clarity, a breakdown work order is indeed necessary when equipment has failed and is causing downtime, while a corrective repair work order is meant for issues that could lead to failure if left unaddressed. It's great that you're distinguishing between the two, as it will help improve our maintenance strategies and reduce unplanned downtime. Maybe we could have a quick refresher session on this to ensure everyone is on the same page?
You’re spot on with that distinction! A corrective repair work order is all about being proactive—catching issues before they escalate—while a breakdown work order kicks in after something has actually failed. It might help to emphasize this difference in training sessions to clear up any confusion; having clear examples of each could really help everyone get on the same page. Plus, clarifying the processes can improve our overall response times and reduce downtime.
You’ve got the distinction pretty spot on! Just to clarify a bit further, a corrective repair work order is intended to proactively address potential issues before they lead to a breakdown, which can really help in minimizing downtime and keeping operations smooth. Meanwhile, the breakdown work order only comes into play when a machine has already failed. It might help to create a quick reference guide or flowchart for everyone at the plant to ensure we're all on the same page about when to use each type of work order. Communication is key!
You’ve got the distinction pretty spot on! A corrective repair order is indeed about being proactive and addressing issues before they escalate, while a breakdown work order comes into play once something has actually failed. It might help to emphasize the importance of communication on the shop floor so everyone understands the urgency of identifying issues early and creating the right type of work order. Encouraging team members to report potential problems can really help reduce downtime!
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Answer: 1. What is the difference between a corrective repair work order and a breakdown work order in plant maintenance? - A corrective repair work order is issued when a possible breakdown is identified during preventative maintenance or predictive maintenance and addressed before any functional failure occurs. A breakdown work order is created after a functional failure has occurred.
Answer: - A corrective repair work order should be issued when a potential issue is identified during routine maintenance to prevent any breakdowns or functional failures.
Answer: - A breakdown work order should be created after a functional failure has occurred in the plant operations, requiring immediate attention to restore functionality.
Answer: - Plant maintenance staff should be vigilant during routine maintenance checks to identify potential issues that may lead to breakdowns and issue corrective repair work orders promptly. In cases where a breakdown has already occurred, a breakdown work order should be initiated for immediate action.
Answer: - Differentiating between these work orders helps in proactive maintenance planning, preventing unexpected breakdowns, minimizing downtime, and ensuring optimal plant performance and productivity.
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