Introduction
Every hour of downtime in a factory or utility system isn’t just lost production—it’s lost profit, broken client trust, and exhausted teams scrambling to fix what should have been avoided. In the Zimbabwean industry, we still see a dominant reliance on reactive maintenance, where systems are only repaired after failure.
In this article, we unpack:
The technical causes behind common failures
The limitations of reactive maintenance
A practical framework to move toward preventive and condition-based strategies
What Is Reactive Maintenance?
Reactive maintenance (RM) is the “run-to-failure” model. It’s fast to implement, but costly over time. It doesn’t account for Mean Time Between Failures (MTBF) or early warning signs from your equipment. Here’s what RM misses:
Heat buildup in control componets like VFDs from dust or blocked cooling fans
Loose terminations causing intermittent faults and arc flash risks
Degraded contactors or relays cycling past their rated duty
Capacitor ageing in motor drives or power supply units (PSUs), that can cause abrupt shutdowns
These are all avoidable through simple, low-cost inspections.
Case in Point: A Preventable Breakdown
One of our clients in the food processing sector recently experienced a full-day shutdown due to a failed variable frequency drive (VFD). The culprit? A single loose wire on the motor. The breakdown halted the packing line for eight hours, leading to missed delivery targets and financial losses. A routine inspection would have caught the issue in minutes—long before it became a crisis.
The Alternative: Proactive Maintenance
Unlike reactive maintenance, proactive maintenance is about prevention. It includes:
Preventive Maintenance (PM): Scheduled inspections, lubrication, re-termination, etc.
Condition-Based Monitoring (CBM): Using vibration, temperature, or runtime data to act before failure
Regular inspection of electrical panels
Tracking the run-time of motors
Monitoring PLC and HMI system logs
Proper labeling and documentation
Root Cause Analysis (RCA): Post-failure analysis to prevent repeat incidents
This approach minimizes risk and extends the lifespan of your equipment. It also allows for repairs to be scheduled during non-peak hours, avoiding disruption.
Sample Monthly Maintenance Checklist (Low-Voltage Panels)
How to Start the Shift
- Log all breakdowns for 60 days
Create a failure map: What keeps failing? When? Why?
- Quantify the cost of downtime
Use internal data to build a financial case for management.
- Build a 3-tier maintenance schedule
Daily operator checks
Monthly inspections
Quarterly panel testing + logs
- Train your team
Even basic VFD parameter checks or overload reset logic can prevent costly callouts.
Benefits of Proactive Maintenance
- Reduced Downtime: Address minor issues before they escalate.
- Lower Long-Term Costs: Avoid emergency service charges and component replacements.
- Improved Safety: Catch faults that can lead to electrical hazards.
- Increased Equipment Life: Prevent stress-induced damage from frequent hard stops or surges.
Conclusion
Reactive maintenance may feel easier in the short term, but it’s draining long-term profitability. At Hoodridge, we’ve seen how even simple changes—like better labeling, regular panel checks, or scheduled downtime for inspections—can reduce emergency repairs by over 40%.
If your factory, municipality, or plant doesn’t yet have a structured maintenance plan, now’s the time to start.
Reliable systems don’t just run—they’re managed.
What Hoodridge Offers
At Hoodridge Industrial Automation, we help clients move from reactive to proactive. Our services include:
- Preventive maintenance audits
- Smart relay and PLC health checks
- Control panel cleaning and re-termination
- Documentation and labeling upgrades
- Custom maintenance schedules
Don’t Wait for Failure
Let’s build a more reliable future—one system at a time.
Contact Hoodridge today to schedule a consultation.
