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Planned vs unplanned maintenance; maintenance plan

Short answer

Planned maintenance is scheduled in advance, lower cost, short downtime, and safer; examples are annual painting and crack sealing. Unplanned maintenance is triggered by breakdown or emergency, with higher cost and long sudden downtime; examples are burst pipe repair or flood-damaged road repair. A good plan requires inventory, priorities, schedule, resources, records, and regular review.

Differentiate between planned and unplanned maintenance with suitable examples. How can a good maintenance plan be formulated? Explain in brief.

Difference

PointPlanned maintenanceUnplanned maintenance
MeaningWork organised and scheduled in advanceWork done without prior planning, when a need suddenly arises
TriggerSchedule, inspection, conditionBreakdown, failure or emergency
CostLower and predictableHigher, unpredictable
DowntimeShort and arrangedLong and sudden
SafetyBetterRisk of accidents
ExamplesAnnual painting, cleaning water tank, servicing lift, resealing road cracksRepair of a burst pipe, collapsed wall, damaged road after flood

Formulating a good maintenance plan

  1. Inventory and survey: list all components, with their age, condition and importance (roof, walls, services, drainage).
  2. Set objectives and standards for performance, safety and appearance.
  3. Identify tasks and frequencies: daily, monthly, annual and periodic, from manufacturers' manuals and experience.
  4. Prioritise by safety, risk and cost; critical items first.
  5. Estimate resources: materials, labour, tools, spare parts, contractors and budget.
  6. Prepare a schedule (calendar or bar chart) and assign responsibility.
  7. Implement by work orders; supervise quality and safety.
  8. Keep records: history cards, inspection reports, costs.
  9. Review and update the plan regularly using feedback and performance data.

✓ Answer checked by Claude Opus 5.5 (high effort)

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