Corrective Maintenance vs Production Continuity
Shift from run-to-failure toward condition-based maintenance under ISO 55001 to reduce unplanned downtime, safety incidents, and emergency repair costs.
CyberTRIZ analysis · OilIndustry contradiction C14-R006 · one of 8,235 worked contradictions published by CyberTRIZ.AI
Regulations
Business Context
Corrective maintenance restores equipment after failures occur, often reducing unnecessary preventive work. However, unplanned repairs interrupt production, require emergency resources, and typically cost significantly more than planned interventions.
The Contradiction
Reducing preventive maintenance lowers planned maintenance effort.
However, greater dependence on corrective maintenance increases production interruptions.
Why the Contradiction Exists
Unexpected failures occur when equipment degrades beyond acceptable operating limits before intervention takes place.
Operational Risks
Emergency shutdowns, production losses, safety incidents, and higher repair costs.
Oil Industry TRIZ Analysis
Maintenance programs should balance preventive, predictive, and corrective activities according to equipment criticality and operational consequences, minimizing emergency interventions.
Applicable TRIZ Principles
Principle 19 – Periodic Action
Principle 23 – Feedback
Principle 15 – Dynamics
Decision Tree
If equipment health remains acceptable, continue monitoring.
If degradation accelerates, perform planned maintenance.
Operational Playbook
Detect degradation.
Assess operational risk.
Schedule intervention.
Complete repairs.
Validate equipment health.
Update maintenance records.
Verification Metrics
Corrective maintenance ratio, downtime, MTTR, equipment availability, and maintenance cost.