Costs & KPIs · Advanced
Analyze Corrective vs. Preventive Maintenance
Learn to compare corrective and preventive maintenance using work order counts and recorded costs for the same period and equipment scope. Interpret each type’s share without assuming that all corrective work is unscheduled.
Understanding the balance between corrective and preventive maintenance is crucial for operational efficiency and cost control. This analysis helps you quantify the impact of each strategy within your organization. By comparing work order counts and associated costs, you can make informed decisions to optimize your maintenance approach.
Where it's available and step by step
Step by step in ManWinWin Desktop
- 1
Open the work order list and establish the period and equipment scope to use for both maintenance types.
- 2
Use the same date basis and work order statuses for both groups so that planned work is not compared with completed work.
- 3
Identify the work types that represent corrective and preventive maintenance in your organisation, keeping planned corrective work in the corrective group.
- 4
Filter the corrective group and note its work order count; repeat for the preventive group without changing the period, equipment scope or status criteria.
- 5
Consult the recorded costs associated with each group and total them separately, using the same cost coverage for both groups and keeping costs not linked to the selected orders outside the comparison.
- 6
Calculate each group’s percentage of the combined corrective-plus-preventive work order count and, separately, of their combined recorded cost; if a combined total is zero, leave that percentage undefined.
- 7
Compare the count shares with the cost shares and note which type accounts for more work orders and which accounts for more spending, treating the findings as a basis for review rather than proof that more preventive work is always better.
Theory and technical background
The Strategic Balance of Maintenance Types
Maintenance strategies typically fall into two main categories: corrective and preventive. Corrective maintenance (CM) addresses failures after they occur, while preventive maintenance (PM) aims to avoid failures through scheduled activities. A common misconception is that all CM is reactive; however, planned CM exists for non-critical repairs or when PM is not cost-effective. The optimal strategy often involves a balanced mix, tailored to asset criticality, operational context, and budgetary constraints, ensuring resources are allocated effectively without over-maintaining or under-maintaining assets.
Key Performance Indicators (KPIs) in Maintenance Analysis
When analyzing corrective versus preventive maintenance, several KPIs are instrumental. Mean Time Between Failures (MTBF) and Mean Time To Repair (MTTR) are vital for understanding asset reliability and maintainability, often improving with effective PM. Maintenance Cost as a Percentage of Asset Replacement Value indicates overall spending efficiency. Analyzing the ratio of CM costs to PM costs provides insight into the effectiveness of PM programs in reducing unexpected repairs. These KPIs help benchmark performance, identify trends, and justify strategic shifts towards a more proactive maintenance culture.
Leveraging Data for Informed Decision-Making
Effective comparison of corrective and preventive maintenance relies heavily on accurate data capture within your CMMS, such as ManWinWin. Detailed work orders, including labor, material, and external service costs, are essential. Consistent coding for work types, equipment, and failure modes allows for robust analysis. The ISO 14224 standard provides a framework for collecting reliability and maintenance data, enhancing data quality. By consolidating and analyzing this information, organizations can identify recurring issues, optimize PM schedules, and make data-driven decisions that reduce overall maintenance expenses and improve asset availability.
Best practices
- Ensure consistent work order classification for accurate analysis.
- Use a fixed, representative period for comparison (e.g., quarterly, annually).
- Include all relevant costs (labor, parts, external services) for each work order.
- Focus on trends over time, not just single-period snapshots.
Frequently asked questions
Why is it important to distinguish between planned and unplanned corrective work?
Distinguishing planned from unplanned corrective work provides a clearer picture of maintenance efficiency. Unplanned work often incurs higher costs due to urgency and lack of preparation, while planned corrective work can be scheduled for better resource allocation and cost control.
How can I ensure consistent cost coverage for both maintenance types?
To ensure consistent cost coverage, establish clear guidelines for what constitutes a cost for each work order (e.g., all labor, materials, and external services directly tied to the WO). Use your CMMS's cost tracking features comprehensively for all maintenance types.
What if my percentage calculation results in an undefined value?
An undefined percentage (e.g., division by zero) indicates that the combined total count or cost for corrective and preventive maintenance in your selected period was zero. This suggests no relevant work orders or costs were recorded for the scope analyzed.
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