Maintenance repairs and operations (MRO)

Get the ultimate guide to planning and scheduling maintenance

What is maintenance repairs and operations?

Maintenance, repair, and operations (MRO) is the process of maintaining and repairing equipment. MRO is also known as maintenance, repair, and overhaul. MRO can be used to ensure everything is working correctly and to prevent future equipment problems. It can also help extend the lifespan of your items if they are correctly maintained.

What is an example of MRO?

An example of MRO in maintenance is replacing an industrial machine's faulty component. Let's say a production line in a manufacturing facility is experiencing issues due to a malfunctioning motor. The maintenance team identifies the problem and determines that the motor needs to be replaced.

Which industries use MRO?

MRO is a critical aspect of various industries. Here are some industries that extensively use MRO practices:

Manufacturing: Manufacturing industries rely heavily on MRO activities to maintain and repair production equipment, machinery, and tools. This includes automotive, aerospace, electronics, consumer goods, and more industries.
Energy and utilities: Power plants, oil refineries, gas pipelines, and other energy and utilities sectors require MRO services to ensure the reliable operation of infrastructure, including turbines, generators, transformers, pumps, and valves.
Transportation: The transportation industry, including airlines, railways, shipping, and logistics, relies on MRO practices to maintain their fleets of vehicles, aircraft, locomotives, and shipping containers. This includes regular inspections, repairs, and replacement of components to ensure safety and efficiency.
Healthcare: MRO is vital in healthcare facilities, including hospitals, clinics, and laboratories. It involves maintaining and repairing medical equipment, such as MRI machines, X-ray equipment, surgical instruments, and patient monitoring systems.
Mining and resources: Mining operations rely on MRO practices to maintain their heavy machinery, drilling equipment, conveyor systems, and processing plants, ensuring uninterrupted production.
Food and beverage: MRO is essential in the food and beverage industry to maintain production lines, packaging machinery, refrigeration systems, and processing equipment, ensuring compliance with quality and safety standards.

Types of MRO

MRO can be categorized into several types based on the nature of the activities involved. Here are some common types of MRO:

Corrective maintenance: This type of MRO focuses on repairing or restoring equipment or infrastructure that has experienced a failure or malfunction. It involves troubleshooting the problem, identifying the root cause, and taking corrective actions to fix the issue and bring the asset back to its normal functioning.
Preventive maintenance: Preventive maintenance involves scheduled inspections, servicing, and repairs performed on equipment and infrastructure to prevent potential failures or breakdowns. It aims to identify and address minor issues or signs of wear and tear before they develop into significant problems, helping to prolong the lifespan and reliability of assets.
Predictive maintenance: Predictive maintenance uses advanced monitoring techniques and data analysis to predict equipment failures or performance degradation. It involves collecting and analyzing real-time or historical data to identify patterns or anomalies that indicate potential issues. By proactively addressing these problems, organizations can minimize unplanned downtime and optimize maintenance schedules.
Planned maintenance: Planned maintenance involves pre-scheduled activities to maintain and service equipment, machinery, or infrastructure regularly. It includes tasks like lubrication, calibration, filter replacements, cleaning, and inspections. Planned maintenance helps ensure optimal performance, reliability, and compliance with regulatory standards.
Emergency maintenance: Emergency maintenance occurs when unexpected failures or breakdowns require immediate attention and repair. It involves rapid response to address critical issues and restore functionality to avoid significant disruptions to operations. Emergency maintenance often incurs higher costs and focuses on a rapid resolution to minimize downtime.
Inventory management: MRO also encompasses managing the inventory of spare parts, tools, and supplies needed for maintenance and repairs. This includes tracking stock levels, procurement, storage, and distribution of necessary items to ensure their availability when needed.

Want to try a CMMS today?

Get started for free

What are the advantages and disadvantages of MRO?

Maintenance, repairs, and operations has many benefits, but it has some disadvantages as well. Below is a table that illustrates some of the advantages and disadvantages of MRO:

Advantages of MRO

Disadvantages of MRO

Increased equipment efficiency: Regular maintenance and repair activities help ensure that equipment and machinery function optimally. This leads to increased efficiency, reduced downtime, and improved overall productivity.
Cost savings: By performing routine maintenance, potential breakdowns or failures can be prevented, avoiding costly repairs or replacements. Proactive maintenance can extend the lifespan of equipment, reducing the need for frequent capital investments.
Enhanced safety: Proper maintenance and repair procedures ensure that equipment and facilities are safe. Regular inspections and upkeep help identify and address potential hazards, minimizing the risk of accidents and injuries in the workplace.
Improved inventory management: MRO involves managing supplies and spare parts inventory. Organizations can optimize stock levels, reduce excess inventory, and prevent stockouts by implementing efficient inventory management systems. This helps streamline operations and minimize costs associated with inventory.
Compliance and regulatory requirements: Many industries have strict regulations and compliance standards. Effective MRO practices help organizations meet these requirements, ensuring legal compliance and avoiding penalties or legal issues.

Investment: Implementing a comprehensive MRO program requires a significant initial investment. This includes the cost of skilled maintenance staff, equipment, tools, spare parts, and software systems. Small organizations or those with limited budgets may find it challenging to allocate resources for MRO.
Downtime during maintenance: Scheduled maintenance activities often require shutting down equipment or temporarily halting operations, leading to downtime and reduced production output.
Complexity and coordination: MRO activities involve managing multiple tasks, schedules, and resources. Coordinating maintenance staff, obtaining spare parts, and scheduling repairs can become complex, particularly in large organizations with numerous assets to maintain.
Skill requirements and training: Skilled technicians or maintenance personnel are required to perform maintenance and repair tasks effectively. Organizations must invest in training programs to ensure their staff members have the necessary knowledge and skills.
Balancing maintenance costs: While regular maintenance can help prevent breakdowns, there is a cost associated with performing maintenance tasks. Organizations need to strike a balance between proactive maintenance and minimizing costs. Over-maintenance can result in unnecessary expenses, while under-maintenance may lead to equipment failures and higher repair costs.

MRO is essential for maintaining many types of equipment

Regular maintenance and the use of MRO parts not only keep equipment operational but also contribute to increased efficiency and productivity. Well-maintained machinery minimizes downtime, reducing the loss of productivity and revenue associated with equipment failures.