How CMMS Can Help You Manage Maintenance

방문운전연수 Maintenance encompasses all actions that are undertaken to keep equipment functioning in a functional state. It involves inspections, testing, servicing, classification of items as to serviceability, repair, and replacement.

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This is especially important for production teams whose performance evaluations are closely tied to productivity goals. Putting off maintenance and relying on emergency repairs only results in more expensive problems down the line.

Preventive Maintenance

Preventive maintenance is a reliable maintenance strategy that helps reduce equipment failures, unplanned downtime, and operational expenses. In this approach, maintenance teams conduct calendar-based inspections to monitor critical assets, ensuring that each asset remains within accepted parameters. Then, they take corrective action, like cleaning or lubricating equipment components, before any issues occur.

While it may seem simple, the execution of preventive maintenance requires planning, resources, and a solid process. It’s also a crucial part of a world-class maintenance program. A good preventive maintenance program focuses on maximizing the life span of a piece of equipment and decreasing downtime for an entire facility. This type of maintenance strategy keeps equipment running efficiently, maintains a high safety level for employees, and minimizes costly repairs or replacements in the long run.

Effective preventive maintenance programs can be executed using CMMS software to ensure that each completed task is documented correctly. CMMS tools can help prevent equipment downtime by scheduling tasks based on real-time data insights. These tools can also track and document maintenance activities and make recommendations for improvement to avoid downtime and other costs.

Performing preventive maintenance on a regular basis can also 방문운전연수 improve productivity and efficiency. This is because it doesn’t require the shutdown of a machine, which is often required when conducting reactive maintenance. It can also decrease the amount of time employees spend waiting for repair technicians to arrive on-site or ship replacement parts from another location.

Predictive Maintenance

When maintenance professionals use predictive maintenance techniques, they can monitor equipment and systems for anomalies, predicting what kind of damage is likely to occur. This prevents catastrophic failures, avoiding downtime and the related loss of productivity and revenue. It also reduces the cost of replacement parts, reduces the need for scheduled outages and minimizes spare part inventory.

To implement predictive maintenance, engineers must develop a statistical or AI algorithm to classify incoming condition indicator data from sensors as either normal or abnormal. These algorithms can be deployed in the field, embedded directly into industrial controllers, or integrated into IT/OT systems to which sensor data is streamed. They can be supervised (training the algorithm with labeled training data corresponding to different failure modes) or unsupervised (training the algorithm on incoming sensor data without any labels).

For example, a maintenance team might choose to monitor vibrations in a centrifugal pump motor. It attaches a vibration meter to the motor and establishes a baseline measurement, visualized in a waveform graph (below). Then, when the system detects a spike in acceleration, it alerts the maintenance team. They can remotely inspect the motor and find that a loose ball bearing is causing it to shake.

This kind of early detection reduces repair costs, avoids a costly plant shutdown and prevents serious injury to personnel. It also extends the useful operating life of machinery, and enables the maintenance department to become a business value creator rather than a cost center.

Condition-Based Maintenance

Imagine a world in which your production line runs smoothly all the time at optimal levels. It’s a world where you get the highest quality products out, keeping customers happy and revenue climbing.

This is the world a condition-based maintenance (CBM) program creates. CBM combines recommended guidelines with repair and performance data to determine when to perform maintenance tasks and what types of tasks to conduct. It differs from preventive maintenance because maintenance only happens when data indicates a deterioration in equipment or the early warning signs of impending failure.

When the sensors on your machines detect an issue, they alert the team and create a work order to resolve the problem. These issues could be anything from a vibration sensor detecting excessive vibration, to an IR camera spotting high temperatures in energized equipment.

These alerts need to be quickly acted upon by the maintenance team to prevent complete failure or further, more costly damage, as well as safety risks for employees. This will entail training the team and investing in equipment to monitor key performance factors.

The biggest challenge with implementing a CBM strategy is the sheer amount of data being collected from multiple sources across your operations. It requires a robust technology and software system to support this, from logging the data to triggering work orders and beyond.

Computerized Maintenance Management System Software

A CMMS software solution can help you manage the day-to-day maintenance work requirements of your facility, equipment or systems. It can also record and analyze data to prepare reports and aid organizational and personnel decisions. CMMS can be deployed on-premises or as a SaaS – software as a service – system hosted by the vendor.

Modern CMMS solutions often offer mobile-enabled interfaces that allow your techs to access their assignments and information from anywhere with an internet connection. This helps keep them connected to the information they need, so they can complete their jobs faster and more efficiently.

CMMS can help you organize, streamline and prioritize work order processing and management to decrease equipment downtime. It can also store performance information and help you make cost-effective “replace or repair” decisions. Some CMMS solutions can also include an inventory module that tracks materials and parts to simplify MRO (maintenance and repair-related) inventory management, improve purchasing accuracy and measure big-picture metrics such as inventory costs and utilization statistics.

A CMMS can also enable you to manage your workforce resources by capturing and tracking work performance data for employees, including time-stamped labor records. Combined with the ability to capture and share photos, video, and audio, this helps your team stay productive on the job site. Many CMMS solutions can also provide safety features that include manual or automatic safety plan numbering and the ability to associate multiple precautions with a specific hazard.