Frequent breakdowns and rising maintenance costs can be a sign that certain equipment is becoming less economical to operate.

Manufacturers should therefore consider maintenance burden alongside purchase cost, energy use, and production impact before deciding whether machinery should be repaired or replaced.

MSMEs evaluating older equipment can review ADEETIE guidance for linking maintenance burden with energy-efficiency upgrades while assessing current energy consumption, equipment condition, financing needs, and expected operational improvements.

A maintenance review should look at repair frequency, spare-part cost, technician availability, downtime, and the effect of repeated failures on production schedules. This can help businesses identify which assets are creating the highest operational risk.

Pharmaceutical manufacturers may also need to consider quality and compliance implications when equipment becomes unreliable. Existing units can review RPTUAS considerations for replacing high-maintenance pharma equipment while planning production, utility, testing, and compliance-related technology upgrades.

Before approving a replacement, manufacturers should generally review:

• Breakdown frequency

• Annual maintenance cost

• Spare-part availability

• Energy consumption

• Production downtime

• Quality or compliance impact

• Remaining useful life

• Replacement and installation cost

Government support may improve the economics of an eligible technology project, but replacement decisions should still be based on measurable operational need.

Reviewing maintenance burden before investing can help manufacturers prioritise critical upgrades, reduce unplanned downtime, and avoid spending capital on equipment that can still operate efficiently.