In manufacturing industries across the globe, an impressive 65% of businesses report experiencing a notable improvement in overall efficiency following the implementation of Computerized Maintenance Management Systems (CMMS). This statistic serves as a compelling justification for the escalating demand for CMMS software in the industry. Notably, this trend has extended beyond large corporations, with small and mid-sized businesses from various sectors, including energy and utilities, increasingly embracing CMMS solutions.
In this article, we will explore the 5 key reasons why investing in CMMS has become imperative for the manufacturing industry.
Within the realm of manufacturing, the assets employed are undeniably intricate and immense in scale. Operating ceaselessly for extended periods, these assets play a pivotal role in determining overall performance. Consequently, it becomes crucial to ensure their perpetual upkeep and maintenance. Neglecting this crucial aspect can result in catastrophic losses stemming from unexpected equipment malfunctions. Given the exorbitant costs associated with manufacturing assets, their easy replacement is simply unfeasible, rendering them equally challenging to resell.
In addition to the evident advantages, such as a substantial 59.5% improvement in equipment effectiveness, a 58.5% reduction in downtime, and an impressive 57.5% enhancement in productivity, the integration of a computerized maintenance management system (CMMS) transcends mere operational efficiency to encompass strategic decision-making. The efficacy of any business decision is heavily reliant on the quality of information upon which it is based. Whether we look at investments in diverse maintenance strategies, efficient allocation of workforce resources, or judicious capital expenditure planning, the timely availability of accurate information assumes paramount significance.
The 3 Most Prominent Maintenance Strategies in the Manufacturing Industry
In the ever-evolving landscape of the manufacturing industry, the implementation of effective maintenance strategies holds the key to maximizing productivity and minimizing disruptions. According to the Plant Engineering 2018 Maintenance Study, which surveyed industry professionals, 3 primary maintenance approaches have emerged as the most prominent choices for manufacturing businesses seeking to streamline their operations.
Preventive Maintenance
The study reveals that a staggering 80% of manufacturing facilities have adopted preventive maintenance as their strategy of choice. This proactive approach involves regular inspections, servicing, and component replacements at predetermined intervals. By addressing potential equipment issues in advance, this strategy significantly reduces the risk of unexpected breakdowns and associated production interruptions.
Run-to-Failure Method
According to the study, 57% of manufacturing facilities follow a run-to-failure approach. This reactive strategy entails running equipment until it fails, and subsequently repairing or replacing it. The run-to-failure method is commonly employed for assets with lower criticality or when the cost of maintenance outweighs the cost of failure. While it minimizes routine maintenance expenses, it does carry the risk of unplanned downtime and productivity losses. Therefore, its suitability depends on the specific characteristics and importance of the equipment.
Predictive Maintenance (PdM) with Analytical Tools
The study indicates that 51% of manufacturing facilities have embraced predictive maintenance, leveraging analytical tools for enhanced efficiency. By harnessing advanced technologies like sensors and data analytics (CMMS), this strategy enables real-time monitoring of equipment health. Through the analysis of data patterns and trends, potential failures can be predicted, allowing for proactive interventions. This data-driven approach empowers manufacturers to optimize maintenance schedules, reducing downtime and enhancing overall equipment effectiveness.
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5 Vital Benefits of CMMS Software in the Manufacturing Industry
The manufacturing industry operates within a complex ecosystem, where the efficient management of maintenance processes directly impacts productivity, cost-effectiveness, and equipment reliability. As technology continues to advance, the adoption of Computerized Maintenance Management Information System (CMMS) has become increasingly crucial for manufacturers seeking to streamline their operations. Here is 5 of the main reasons why CMMS software is important for the manufacturing industry:
Enhanced Maintenance Planning and Cost Effectiveness
One of the primary reasons manufacturers invest in CMMS software is to optimize maintenance planning and allocate resources effectively. According to the Plant Engineering, 52% of facilities allocate up to 10% of their annual operating costs to maintenance processes, with 35% dedicating even more. By leveraging CMMS software, manufacturers can streamline their scheduling and preventive maintenance activities, ensuring that maintenance tasks are efficiently planned and executed. This proactive approach minimizes costly breakdowns and reduces the likelihood of unscheduled downtime. With the ability to track maintenance history and predict future requirements, CMMS software empowers manufacturers to make data-driven decisions, ultimately leading to improved cost effectiveness and enhanced operational efficiency.
Proactive Equipment Management and Reliability
In the manufacturing industry, equipment reliability is paramount. Unscheduled downtime can have severe repercussions, impacting production schedules, and ultimately customer satisfaction. The Maintenance Study by Plant Engineering highlights that aging equipment is the leading cause of unscheduled downtime, accounting for 44% of the cases.
By utilizing CMMS software, manufacturers can implement preventive maintenance strategies that are tailored to each piece of equipment's specific needs. These strategies include regular inspections, servicing, and component replacements at predetermined intervals. With the ability to track equipment performance and set maintenance alerts, manufacturers can identify and address potential issues before they escalate into costly breakdowns. This is a valuable functionality for manufacturing plants that have critical machinery. By leveraging advanced analytics capabilities, the software detected early signs of deterioration in a crucial production line component. The maintenance team promptly intervened, preventing a major breakdown that could have resulted in days of downtime. This proactive approach not only saved the company substantial repair costs but also ensured uninterrupted production and customer satisfaction.
Streamlined Workforce Management and Training
Efficient workforce management is vital for manufacturing facilities to optimize maintenance operations. The Plant Engineering 2018 Maintenance Study reveals that maintenance teams receive training primarily in safety (84%), basic electrical skills (68%), and mechanical skills (67%). CMMS software plays a crucial role in facilitating workforce management by streamlining communication, task assignment, and tracking. Manufacturers can assign work orders to maintenance technicians, monitor their progress, and ensure that tasks are completed on time. The software enabled them to assign maintenance tasks based on technicians' skill sets and availability, resulting in optimized resource allocation. Furthermore, CMMS software can provide documentation and step-by-step instructions for complex maintenance tasks, ensuring that maintenance personnel have the necessary guidance and knowledge to perform their duties efficiently.
This centralized system eliminates the need for manual paperwork and streamlines the entire maintenance workflow. Also, by equipping the workforce with the necessary tools and information, CMMS software enables manufacturers to improve workforce efficiency, reduce errors, and enhance overall productivity.
Data-Driven Decision-Making and Analytics
In today's data-rich environment, leveraging analytics and real-time insights has become crucial for manufacturers seeking a competitive edge. CMMS software offers robust analytical capabilities, allowing manufacturers to gather, analyze, and interpret maintenance data. By integrating CMMS software with advanced analytics tools, manufacturers gain valuable insights into key performance indicators, equipment health trends, and maintenance costs. This data enables them to make informed decisions regarding asset performance, maintenance strategies, and resource allocation. Manufacturers can identify critical areas for improvement, optimize preventive maintenance schedules, and align maintenance activities with production requirements.
Outsourcing Management and Monitoring
Many facilities rely on outsourcing the whole or a portion of their maintenance operations to external suppliers. According to Plant Engineering, the average facility outsources 20% of their maintenance operations. The primary drivers behind this decision are the lack of time/manpower and the absence of specific skills among the current staff. To effectively manage and monitor these outsourcing partnerships, manufacturers can turn to Computerized Maintenance Management System software, which offers a range of advantages in supplier collaboration and performance tracking.
CMMS software acts as a centralized platform, enabling seamless communication and coordination between manufacturers and their outsourcing suppliers. It integrates all maintenance operations, providing enhanced visibility and control over outsourced activities. Streamlined work order management facilitates task assignment, progress monitoring, and completion tracking, ensuring timely and standardized maintenance execution. By capturing data on response times, resolution rates, and service quality. Additionally, it facilitates comprehensive record-keeping for regulatory compliance, auditing, and historical reference. Manufacturers can effortlessly access and retrieve information related to outsourced tasks, ensuring adherence to industry standards and facilitating seamless audits.
The utilization of CMMS software has become paramount in the manufacturing industry, driven by the need for enhanced maintenance planning, proactive equipment management, streamlined workforce operations, data-driven decision-making, and supplier management. By leveraging CMMS software, manufacturers can optimize their maintenance processes, reduce costs, improve equipment reliability, and ultimately achieve operational excellence. With the ever-increasing demands of the industry, investing in CMMS software has become an essential strategy for manufacturers aiming to stay competitive and thrive in the dynamic manufacturing landscape.
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