Aren’t you tired of frequent machine breakdowns and expensive repairs?
Machines are an important part of your business and every repair comes with a hefty hit to your budget. Commonly, equipment is only attended to if there are sudden breakdowns that require immediate attention. This leads to unplanned downtimes and overtime call-out fees. But how can your business transition from being reactive on breakdowns to preventive maintenance?
Here are 10 sure ways to level up your maintenance strategy:
- ASSEMBLE THE PREVENTIVE MAINTENANCE MANAGEMENT TEAM
When possible, it is best to construct a specialized team or department to be in charge of plant maintenance. They will need to create the equipment check-up schedules, hold regular meetings about ongoing and new projects and deploy staff to handle those projects.
- DO PREVENTIVE MAINTENANCE ANALYSES
It is important to know the causes of a machine breakdown to prevent it from happening again. One of these is Risk-cause Analysis (RCA), which is the process of identifying root causes of the problems by first getting to the “root” of the generic problem, and then asking the ‘why’ question until it cannot be answered anymore. Another is Failure Modes and Effects Analysis (FMEA), which is an approach of evaluating when and where your equipment and staff will fail and even develop solutions that will prevent it in the future.
- GET A CMMS FOR BETTER SCHEDULING OF MAINTENANCE AND REPAIRS
A Computerized Maintenance Management System (CMMS) is an essential software tool for planning maintenance and repair schedules, tracking the occurrence of breakdowns and getting up-to-date reports. It also works as a notification system that will alert the department if there are breakdowns; this system, in turn, will classify which projects are urgent and which are not.
- INTRODUCE KEY PERFORMANCE INDICATORS (KPIs)
Set goals for your team to assess the performance of both equipment and staff. It will help your team to know what goals they need to achieve and what to expect in their future assignments.
- GET EQUIPMENT FEEDBACK
Equipment Feedback forms should be part of routine equipment check-ups to assess the frequency of breakdowns. It will also serve as historical data that will be useful for future management decisions.
- INCORPORATE THE CLAIR STRATEGY
For the effective execution of scheduled inspection and maintenance, it is important to follow CLAIR:
- START SMALL
When trying new things, especially in business, it is important to start small. Try applying preventive maintenance to a small number of machines, analyze the data and familiarize your team with it.
- CONSTANT TRAINING OF STAFF WITH PROPER MOTIVATION
It is important to cultivate the skills of the maintenance team. Start by offering them training on how Six Sigma can be applied within the department or let them take the Certified Maintenance and Reliability Professional Exam (CMRP) offered by the Society for Maintenance and Reliability Professionals.
- CONSTANT MONITORING AND EVALUATION OF MANPOWER AND EQUIPMENT
You have already established the array of analyses to be applied by your team, assembled the right people and made a set of KPIs to achieve. The only thing you need now is to properly monitor these changes and evaluate them against your previous data (data collected before the transition to preventive maintenance). The historical data you retrieved from previous maintenance reports will be a huge help when comparing it to the present conditions of the machines, as it will offer an overview of what needs to be accomplished and what needs to be remedied.
- BE OPEN TO CHANGE
Aside from incorporating these changes into your company, it is important to be open to new changes in the field of maintenance that apply to your department’s goals. Never be afraid of change and always look for new ways to improve the efficiency of your staff and maximize your equipment.
Transitioning from being reactive to preventive is a great step in improving the maintenance framework of your business. Aside from the peace of mind it will provide, the benefits of this transition include reduced long- and short-term overall costs (as much as 18% savings), fewer breakdowns and maximized equipment uptime.