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Pie Chart

Currently more than 55% of maintenance resources and
activities of an average facility are still reactive in nature.

Reactive  Basically the "run it till it breaks" maintenance mode.


  • Lower initial costs
  • Requires fewer staff


  • Increased costs due to unplanned downtime of equipment
  • Increased labor costs, especially for untimely repairs and replacements
  • May increased costs associated with repairs and replacements
  • May result in secondary equipment or process damage
  • Is an inefficient use of staff resources

Preventative   Actions based on time schedules or machine run time.


  • Is cost effective in many capital intensive processes and equipment
  • Provides flexibility for the adjustment of maintenance periodicity
  • Increases component life cycle
  • Generates energy savings
  • Reduces equipment and/or process failures
  • Results in an estimated 12% to 18% cost savings over that found in a reactive maintenance program


  • Does not eliminate catastrophic failures
  • Is more labor intensive
  • Includes performing unneeded maintenance activities, which has the potential to result in incidental damage to components

Predictive   Actions based on actual condition of the equipment, rather than a time schedule.


  • Provides increased component operational life and availability
  • Allows for preemptive corrective actions
  • Results in decrease in equipment and/or process downtime
  • Lowers costs for parts and labor
  • Provides better product quality
  • Improves worker and environmental safety
  • Raises worker morale
  • Increases energy savings
  • Results in an estimated 8% to 12% cost savings over which might result from a predictive maintenance program


  • Increases investment in diagnostic equipment
  • Increases investment in staff training
  • Savings potential is readily seen by management


Resource — U.S. Department of Energy/Federal Energy Management Program.