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What is Maintenance Workflow?

What is Maintenance Workflow?

Maintenance workflow is the step-by-step process that gets initiated by some trigger event to the point where the action is closed out. For example, in a typical maintenance operation, a trigger event could be a report of faulty equipment. The step-by-step workflow process would include the generation of a maintenance order, the planning of the task, the execution of the repair and the reporting at the end of the job. Every organization has a workflow process whether it is officially documented or not; there is always a standard way to get things done. When this process is not well-defined, it can lead to frustrations on the part of employees trying to get their jobs done as well as major inefficiencies that are costly to the organization over time. In comes maintenance management software…

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Benefits of Manufacturing Maintenance Software

Benefits of Manufacturing Maintenance Software

Maintain equipment, minimize downtime, meet production demands, manage inventory levels, monitor staff productivity, comply with regulatory standards, etc. etc. The list of maintenance demands in a manufacturing plant is nearly impossible to meet without the help of computerized maintenance management systems (CMMS). Manufacturing CMMS software automates the process of maintaining assets to help simplify operations, maximize uptime and control costs.

Many manufacturing plants are relying on outdated systems or maintenance spreadsheets to keep tabs on their equipment and other important aspects of production. In doing so, they run the risk of premature equipment failure, production lags, increased downtime and, ultimately, the loss of business. Consequently, competitors utilizing modern manufacturing CMMS software are more successful.

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Emerging Trends In Maintenance Space And Their Relevance For Reliability Professionals

Emerging Trends In Maintenance Space And Their Relevance For Reliability Professionals

As we enter 2020, it’s evident that many of the changes that are sweeping through maintenance management will continue. The major push behind these changes includes the need for improved resource allocation, optimization of capacity, and increased safety performance/compliance.

With that in mind, this is an ideal time to review some of the biggest topics and trends in maintenance that are shaping maintenance practices and consider their relevance for reliability professionals.

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Components of an Effective Maintenance System

Components of an Effective Maintenance System

If you are ever in the fortunate position of developing a maintenance system from the beginning, the list below will help you focus your efforts. Maintenance systems in small business, develop by default and without much forethought. This list puts together, in one place, the important components of a workable maintenance system. [Read more…]

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The 6 Things Every Maintenance & Reliability Program Needs To Achieve Sustained Results

insanityquoteI want my customers to be successful, every one of them. Yet there are times I can see the writing on the wall and I know as hard as I might try to show them a clear path to what it takes to be successful they have their own plan. Some of them are so complex that people become confused just trying to make sense of them, and others get so hung up in the minutiae of even the simplest of steps like listing a 3 part failure mode they will word-smith themselves to a point where folks just give up. I find myself asking “why do people have to make what is really so simple into something that appears to be complex?” [Read more…]

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Uptime: Managing Failures Before They Occur

Uptime: Managing Failures Before They Occur

Being proactive with your assets is all about managing failures before they occur. You can reduce or eliminate the consequences of failure by forecasting what is likely to happen and deciding in advance about what to do about it.  The advantage to doing this is that major business impact due to equipment breakdown can be avoided.  High performing companies manage proactively – they foresee and avoid problems. It’s good for business! [Read more…]

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What is Criticality Analysis? How Does it Work?

What is Criticality Analysis? How Does it Work?

Understanding the risks allow effective mitigation plans to be put in place

Where is your biggest risk to the site? If you can’t answer that, than your maintenance program is most likely not adequate.   As previously discussed, an effective maintenance program must align with business and its needs. A criticality analysis allows the site to understand where there are risks that must be managed. [Read more…]

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Capital Asset Management: Setup — part 2

Capital Asset Management: Setup — part 2

The rest of us are missing the boat!

Check out part 1, too.

RCM has two potential uses – to set you up for success or to regain success from the jaws of failure.
Regardless of when you use it though, RCM alone isn’t enough to get all the benefits. Applying it after the systems are in service, to recover shortfalls in performance, and then failing to follow up on RCM’s results only delivers part of the benefit. That’s where the aircraft and nuclear industries and the military have it right – they take those extra needed steps. The rest of us don’t! [Read more…]

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That Won’t Work Here! How to Overcome the Top 5 Excuses

That Won’t Work Here! How to Overcome the Top 5 Excuses

One of the most challenging aspects of being a consultant is addressing the musings of those who have accepted defeat.

With a smile of course; and friendly reassurance that you have in fact worked with companies who were worse off and with some training, confidence and a sound business plan they were able to turn things around to a point where people actually enjoyed coming to work. [Read more…]

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Increase Productivity and Competitiveness with MRO Technology – Part 2

Increase Productivity and Competitiveness with MRO Technology – Part 2

Excluding primary practices that still prevail in most industrial companies, the evolution of MRO Materials Management Technology can be summarized in three technological waves, as shown below.

First Wave: Conventional Technology 

There are many grave technological limitations. However, in view of room limitation, I will mention just two of the most relevant and easy to understand limitations. [Read more…]

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Increase Productivity and Competitiveness with MRO Technology – Part 1

Increase Productivity and Competitiveness with MRO Technology – Part 1

In search of excellence in MRO Materials Management (indirect materials / spare parts), I have noticed two curious facts.

First, even in developed countries, industrial companies and providers of ERPs (enterprise management systems) are technologically very backward in this specialty.

Second, those very little companies or experts who developed differentiated technology keep it safe guarded as a trade secret.

This exposure results in considerable accumulation of knowledge and expertise, and a unique set of observations and conclusions which certainly could not fail to be shared with the concerned community.  [Read more…]

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Linking RCM Facilitation with Effective Maintenance Program Implementation

Linking RCM Facilitation with Effective Maintenance Program Implementation

Most of us would agree that there is a new global economy being forged right now in the manufacturing sector.

Inevitably, this translates to a renewed focus on transferring more business value to the customer. Central to this will be linking RCM (Reliability Centered Maintenance) facilitation with effective maintenance program implementations.

In short, the difference between what we, as RCM Facilitators, have been doing in the past and what we will be doing from now on is: a strong emphasis on what tactics are required in order to achieve the failure management strategies an RCM Team defines.

That is, we will conduct the decisions phase of the analysis somewhat differently. (i.e. The 3rd pass through when walking-the-dog in an RCM analysis) [Read more…]

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The Top 5 Signs of a Reliable Plant

The Top 5 Signs of a Reliable Plant

Having visited hundreds of manufacturing plants in the last 15 years, someone recently asked me if there were any traits the most reliable plants all had in common.

I have listed below the top 5 signs of a reliable plant.

Sign 1 – The plant is clean! 

The plants that are top performers are clean all of the time, clutter is unacceptable, and the tasks required to keep the plant clean are routine business. [Read more…]