Planning and managing industrial maintenance are not an easy task and that is why many companies decide to implement CMMS software. Next, Jordi Ruiz, Lean Transforma consultant, explains the advantages of maintenance solutions such as MapexMM and how to get the most out of them.
Industrial maintenance planning and management
How can companies achieve efficient maintenance management?
First of all, efficient maintenance management has to be focused to eliminate breakdowns with good containment and analysis of them. Afterwards, work must be done to guarantee and extend the useful life of the equipment, especially those that play a critical role in the production processes of the factory.
In parallel with the containment and reduction of breakdowns, it is important to carry out a preventive maintenance strategy. By acting before a breakdown occurs, you increase equipment reliability and reduce costs.
Consequently, you can gradually divert resources, previously invested in corrective maintenance, to preventive and predictive maintenance measures. The latter is a maintenance based on the analysis of specific equipment variables, which can reveal when the machine is likely to break down.
What are the most common challenges faced by industrial companies in managing the maintenance of their factories?
As consultants, we basically encounter companies that are highly focused on breakdown management, but do not actively manage these breakdowns or analyze them thoroughly to prevent recurrences.
On the other hand, we see that, in the majority of cases, a notable lack of time and resources exists to design and implement a good preventive maintenance plan. This prevents organizations from starting to prioritize preventive actions, which are always less expensive than corrective ones.
The implementation of a CMMS
What are the main benefits of implementing CMMS software in industrial companies?
CMMS software enables industrial companies to capture, manage and store a large amount of data on factory maintenance processes. Thanks to this, organizations can easily view relevant information in real time, and make decisions much more effective and faster.
In addition, a CMMS solution helps companies focus on the biggest issues, keep every last maintenance cost under control, and efficiently manage spare parts.
What are industrial companies’ concerns when contracting CMMS software?
Above all, that the solution is implemented and then not used. After all, CMMS software is only beneficial if you know how to use it efficiently and take full advantage of all its functionalities. On its own, it contributes next to nothing; it must be complemented by sound management.
What advice would you give companies implementing CMMS software? Which industrial maintenance KPIs are the most relevant?
My advice is that, before implementing CMMS software, be clear on what you want to achieve with the tool; how you want to manage maintenance; what metrics you want to focus on; and what information you want to visualize and what you need it for ultimately.
In terms of the most relevant industrial maintenance KPIs, it is essential to keep the Mean Time Between Failures (MTBF) and Mean Time To Repair (MTTR) under close scrutiny.
It is also very important that, with the help of the CMMS, you track repetitive breakdowns, the degree of compliance with preventive maintenance and the costs of each of the maintenance processes.
What to keep in mind when choosing a CMMS supplier?
When it comes to choosing a CMMS software, make sure that it is a powerful, easy-to-use, intuitive solution that has a user-friendly interface. Now more than ever, you need a multiplatform solution that incorporates a version for mobile devices.
Finally, a CMMS should be able to interface with other production and quality management software to gain a comprehensive picture of the factory’s operations.
Applying Lean Manufacturing in industrial maintenance
What is the relationship between Lean Manufacturing and efficient industrial maintenance management?
The Lean Manufacturing methodology encompasses all areas of a factory, including maintenance management. If a company wants to improve its process efficiency, minimize waste, eliminate non-value-added activities and increase customer satisfaction, it must have equipment that works at full capacity and does not generate quality problems.
All this is particularly relevant in companies where machines play a pivotal role. If they do not manage maintenance efficiently, production process issues will occur very frequently.
Which sectors are leading the way in the application of Lean Manufacturing in industrial maintenance?
Mainly the automotive industry and, more and more, the food industry. These sectors are highly competitive and generate large amounts of data that must be managed and leveraged.
As specialists in Lean Manufacturing, how do you approach the implementation of this management model in an industrial company?
First, we listen to the client to find out what problems, concerns and future strategies they have. Afterwards, we make an on-site assessment of the current situation in terms of processes, machinery, human resources and the production plant in general. And, from here, we establish several paths for improvement; one of them could be maintenance management and the implementation of a CMMS software.
