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Examples of emergency maintenance in the industrial setting

In the industrial setting, emergency maintenance is required to avert potential disasters that arise as a result of failed control measures or failed assets in industrial companies. Unfortunately, whether they happen by accident or due to negligence or incompetence, industrial emergencies can result in great damage, injury, and even loss of life. Some examples are:

  • fire outbreak
  • (poisonous) gas leak
  • unexpected failure of electrical power generator  
  • steam boiler explosion
  • failure of a critical asset that brings the whole production to a halt

How to minimize the number of emergency maintenance requests

Situations that give rise to emergency maintenance can never be completely eliminated, but there are ways to significantly reduce their frequency and mitigate some of the associated risks.

The most effective way to reduce the number of emergency maintenance requests is to have a solid proactive maintenance strategy that will catch and address emerging issues before they escalate into major emergencies.

There are many preventive maintenance strategies you can employ:


Preventive maintenance 

Condition-based maintenance (CBM)

Predictive maintenance (PdM)

Total productive maintenance (TPM) 

Combining any of these strategies with a good CMMS software will enable you to have complete control over your maintenance operations, as well as speed up the response when an emergency maintenance situation does eventually happen.

Other ways to reduce the occurrence of emergency maintenance situations include:

  • having properly trained technicians performing quality work
  • having properly trained machine operators and other employees that come in contact with dangerous and/or critical assets
  • defining clear operating procedures and maintenance checklists technicians can follow
  • using equipment/tools/machines as recommended in their respective manuals
  • using replacement parts from the original manufacturer

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