10 Real-World Maintenance Truths Every Technician Should Know

Every seasoned maintenance professional has likely been dismissed at some point as “out of touch with the real world.” Below are the candid observations that separate theory from practice on the shop floor.

• Paging systems are almost always occupied by ongoing maintenance requests, making it difficult to place a new call.
• Technicians often carry multiple beepers because a single unit is usually in use.
• Responsive communication is critical—handling several pages simultaneously is a daily challenge.
• Yellow recovery carts with flashing lights, sirens, and sometimes colorful uniforms are a common sight.
• Planning and scheduling are embraced when a one‑day turnaround on work orders is realistic.
• In the past, a short‑order cook was the closest person who could manage a maintenance schedule.
• “We’ll address preventive maintenance later; repairs are higher priority,” is a familiar refrain.
• Some argue that maintenance must be proactive, yet projects often crowd out equipment upkeep.
• Voice mail, e‑mail, or even personal calendars are frequently treated as the official schedule.
• A backlog so large that parts were sold to a lumber company illustrates extreme overrun.
• Strategic focus on business support is agreed upon, but most see it as the ability to fix emergencies faster.
• Cost concerns are postponed until the end of the month, when budget overruns become a headline.
• Permanent contract drivers are hired specifically to collect parts from suppliers and airports.
• Rarely do parts get found in the room; it is faster to purchase them on the spot.
• When a mechanic is urgently needed, the receiving dock is often the first place to locate one.
• At any moment, more staff search for or buy parts than actually work on equipment.
• Parts rooms have been expanded to accommodate the volume of workers searching for components.
• Suppliers that deliver only once a day are considered impractical.
• When asked how maintenance is scheduled, many cite the ‘S*** Happens’ mantra from “Forrest Gump.”
• Weekly maintenance schedules are rarely updated because the work is always deferred to next week.
• Some machines may require continuous maintenance to the point of never being production‑ready.
• One technician regularly works overtime, leaving his personal life strained.
• Audio paging has replaced beepers for emergencies because it conveys urgency more effectively.
• Police inquiries about missing mechanics highlight the high turnover and hectic schedules.
• Hardware bins overflow with unused nuts, bolts, and fittings, while the necessary items are scarce.
• Low‑priority work orders are assigned with a “when you have time” mindset, but managers demand completion by noon.
• A planner with hands‑on mechanical expertise can streamline work, yet managers question allocating him to paperwork.
• Operators propose minor improvements, but they are often deprioritized in favor of major projects.
• A role‑clarification meeting clarified that breaking equipment falls under operations, while maintenance is responsible for repairs.
• Informal joint meetings between maintenance and operations reveal common ground and shared priorities.

About the Author

John Crossan is a consultant who retired after 30+ years at Clorox, where he led manufacturing and maintenance improvements across 30 plants in the U.S. and Canada. Prior to Clorox, he held operational and engineering roles at Johnson & Johnson and Burndy Corporation. Contact him at john@johncrossan.com or visit www.johncrossan.com.