Repeat Failure
A repeat failure is the recurrence of the same or closely related failure on an asset within a defined review period.
What this term means in maintenance
A repeat failure is the recurrence of the same or closely related failure on an asset within a defined review period.
Why repeat failures matter
Repeat failure may indicate:
- Incorrect diagnosis
- Temporary repair
- Poor workmanship
- Wrong part
- Uncontrolled root cause
- Inadequate testing
- Weak PM task
- Operating condition outside limits
Practical example
A pump seal is replaced three times in six months. The repeat-failure review finds shaft misalignment and pipe strain that were not corrected during earlier repairs.
Defining repeat failure
The organization should define:
- Review period
- Same asset or asset class
- Same failure mode
- Same component
- Linked follow-up work
- Temporary versus permanent repair
Useful records
Linking work orders allows users to see earlier symptoms, actions, parts, labor, downtime, and root cause.
Common mistake
Counting only identical failure codes can miss repeated problems recorded using different descriptions or generic codes.
How this term differs
Repeat Failure is recurrence of the same or substantially similar equipment failure. It is related to Repeat Work Percentage, First-Time Fix Rate, and Chronic Failure, but these terms describe different records, measures, roles, strategies, or decisions and should not be used interchangeably.
Related concepts
Related maintenance terms
Keep exploring connected CMMS, reliability, and maintenance planning terms.
Chronic Failure
A chronic failure is a recurring equipment problem that persists over time and is often accepted as normal despite its cumulative impact.
Bad Actor Asset
A bad actor asset is equipment that repeatedly creates disproportionate failure, downtime, maintenance cost, safety risk, or operational disruption.
Root Cause Analysis
Root cause analysis is a structured investigation used to identify the underlying conditions that allowed a failure or problem to occur and determine actions that reduce recurrence.
Glossary FAQs
- What is a repeat failure?
The recurrence of the same or related failure on an asset within a defined period.
- What causes repeat failures?
Poor diagnosis, temporary repairs, wrong parts, workmanship, weak testing, or uncontrolled root causes.
- How should repeat failures be tracked?
Link related work orders and use consistent failure information and review periods.