unplanned maintenance

**Unplanned Maintenance** refers to emergency equipment repairs triggered by unexpected failures, as opposed to scheduled preventive maintenance. ## What Is Unplanned Maintenance? - **Trigger**: Equipment breakdown, out-of-spec production, safety event - **Impact**: Production stop, queue buildup, missed delivery - **Cost**: 3-10× higher than equivalent planned maintenance - **Metrics**: MTTR (Mean Time To Repair), unplanned downtime % ## Why Reducing Unplanned Maintenance Matters Every hour of unplanned downtime in a semiconductor fab costs $50K-200K in lost production. Prevention through predictive maintenance pays massive dividends. ```svg Maintenance Strategy Comparison:Reactive: Run to failure → Emergency repair → Resume ████████████╳───────────────────██████████ ↑ Long unplanned downtimePreventive: Scheduled PM → Brief planned stop → Resume ████████████│─│████████████████████████████ ↑ Short planned maintenancePredictive: Monitor → Predict → Plan optimal timing ████████████████│─│███████████████████████ ↑ Minimal disruption ``` **Unplanned Maintenance Reduction**: - Implement predictive maintenance (sensor monitoring) - Stock critical spare parts - Cross-train maintenance technicians - Root cause analysis to prevent recurrence

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