How to Overcome the Biggest Maintenance Challenges in Manufacturing Industry in 2022

How to Overcome the Biggest Maintenance Challenges in Manufacturing Industry in 2022

How to Overcome the Biggest Maintenance Challenges in Manufacturing Industry in 2022

Maintenance work in the manufacturing industry is always a big challenge. Every business has a different set of needs, depending on the context of the manufacturing process. Resource shortages and increasing workloads are one thing, but the constant pressure is always there too.

There are many ways to overcome the biggest maintenance challenges in manufacturing. With technology evolving and several maintenance processes like predictive maintenance becoming much better over time, here are x ways to overcome maintenance challenges in 2022.

Challenge #1: Increasing Operational Efficiency

One of the biggest challenges of modern maintenance teams in manufacturing is increasing their operational efficiency and cutting on downtime. Inaccurate weather forecasts, delays in production, and even unexpected issues from human errors can be a big problem.

Maintenance management teams need to balance several factors, including predictive, corrective, preventive, and even replacement actions. This will allow the management to maximize asset productivity over mid to long-term periods at an optimized cost.

To resolve these issues, companies need to equip their maintenance managers with a deep knowledge of the equipment and facilities they care for. The knowledge should include asset specifications, OEM recommendations, manuals, and even guarantees. These should help create effective maintenance strategies over time.

Challenge #2: Lack of Standard Procedures

Maintenance procedures are a vital part of the manufacturing industry, and they are part of a routine. However, the issue with most plants is the lack of standards within this area. Sure, some standards help decrease plastic consumption in businesses, but there are rarely any maintenance standards, if at all.

Lack of standard procedures, together with variability in maintenance needs for each equipment, can make teams lose time. Standard operating procedures (SOP) need to codify all maintenance procedures and define everything, answering the “what, who, when, and hows” of the entire process.

Companies would need to use SOP to eliminate the vagueness of the entire maintenance process. Standards can also ensure that everything is replicable for other teams for quick and easy work, rather than figuring everything themselves.

Challenge #3: Operational Costs

Many maintenance managers look towards controlling the costs of their entire operation. Companies usually put a maximum of around 5 to 10% of their total budget towards maintenance. Depending on the size of the company, this can be a paltry sum that won’t afford the company the maintenance they need.

This results in poor maintenance for the company, with only enough to perform reactive maintenance to keep their assets online. Sure, there is manufacturing equipment that only needs reactive maintenance but heavy equipment would need preventive maintenance to work.

Keeping your maintenance budget under control is possible by streamlining your maintenance tasks. By simplifying the entire process and removing any unnecessary tasks, you can keep the costs down. Streamlining differs for each company, but you want a process that only takes fewer than half a dozen steps at most.

Challenge  #4: Cross-Functional Teamwork

It takes teamwork to effectively manage a team and help them run like clockwork every time. It’s hard to coordinate a group, especially those with embedded functional categories and their own culture within the manufacturing plant.

Business owners will likely see a problem combining teams with shared responsibilities in keeping the company’s assets in working order. It’s even likely that teams don’t communicate with each other beyond the cursory exchanges they have to do at work.

It’s important to foster teamwork and camaraderie across functional categories to improve maintenance procedures. As maintenance relies a lot on information exchange across different teams, the company must build rally points to reduce operational expenditures and institute new lines of communication.

Challenge #5: Lack of Training

Maintenance challenges stem from a team that is not ready to “answer the call.” If you have a small maintenance team, it can be hard to have a portion of the team do training while others take extra responsibilities that may even be beyond their skill level.

Regardless, companies would want to take on the slight delay in maintenance to help their teams gain extra training. Additional training can help deal with disruptive infrastructure issues and limit unforeseen circumstances within the team.

The Bottom Line

It’s almost impossible for companies to plan for all maintenance challenges. Then again, it’s crucial for companies to control areas they are having difficulties with and create preventive maintenance plans that will help prolong the life of their assets. This saves time and money that is critical in any manufacturing business.

To Automate Your Preventive Maintenance Process

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Management System for Free

How to Maintain Operational Consistency with Cloud, Web & Mobile App based EAM while on the move

How to Maintain Operational Consistency with Cloud, Web & Mobile App based EAM while on the move

How to Maintain Operational Consistency with Cloud, Web &
Mobile App based EAM while on the move

EAM & its usefulness

Enterprise Asset Management(EAM) optimizes business value by maintaining operational consistency. Operational consistency covers consistency in production, quality, processes, safety practices, regulatory compliances, work handover between teams with good & effective communication, delivering instant help to technicians and field work etc.

EAM does the central organization of the information. In addition to this, you can find the details regarding the availability and maintenance of the assets in the manufacturing sector. It focuses on centralizing information to facilitate and digitize maintenance management with automation and covers and manages the entire asset lifecycle from acquisition to disposal.

How does EAM work ?
  • EAM makes it convenient for people to use the data on maintenance in their business. EAM comes with the following capabilities,
  • Manages resources and labor: Track the availability of the labor and staff in the company by using the EAM software. It is ideal for all business houses- be it small, medium or large. The owner can check the presence of the employees in the company anytime, organize shifts.
  • Preparing the registry of assets: It stores the information related to the assets, such as the hierarchy of assets, costs, availability, documentation, and registration. Location and position of the material that is available in the factory at any given moment can be captured and stored.
  • Prepare the work orders & manage them: The main functions of the EAM include preparation of the work order number, order type, remedy codes, materials used, automation of the raw material management, and labor.
  • Parts Management: Automation of spare part stock is becoming convenient for the staff to track all the records on time with minimum re-order level alerts which help in striking a balance for maintenance of stock levels. Accordingly, they can order the materials on the requirement of their business.
  • Reporting and Analysis: You can generate the reports and do their proper analysis anytime with the help of the EAM. Details are available in the different categories, including assets, inventory availability, information regarding the assets, and material costs. Use all this available information anytime to decide on business expansion.
Faster Spare Dispatch

Innomaint provides the provision to store spares at customer location for quicker dispatch and faster fixes, Facility Managers can sanction spares on behalf of Customer Head. This may be helpful in cases were customer is not proficient with usage of the application.

Real-time precise asset tracking

Dashboard allows you to compare the outstanding maintenance tasks & breakdowns between any two customers and is customizable. You can drag and relocate individual widgets. Our EAM Software helps you to precisely identify the exact current location of an asset. This is especially useful to track assets that are frequently moved within the building or premises.

You can achieve all those with InnoMaint EAM.

The history behind the existence & use of the EAM

It wasn’t easy to do the asset and inventory management in the industries before the coming of the CMMS/EAM system. People buried all the essential information in the papers. At times, it becomes tough for them to locate the desired details for official purposes.

Now, things are becoming convenient for them with the help of the EAM. They can put all the information in the EAM software regarding the inventories, asset details, and work orders. The staff can check them anytime when they need time using Mobile app.

It saves their effort and time in maintaining all the information in a proper place. EAM has gained greater prevalence in middle-sized business ventures in the 1980-1990s. People can share all the details regarding the business with their team at the local networking system. Furthermore, it offers greater functionality, speedy implementation, easy-to-maintain things, and data security.

About the Author:

Nitin Gupta is a voracious reader and an even passionate writer. Having worked with numerous medical billing software and MNCs across the world, he really has very to the point and enthralling insights about the industry and the people working in them.

Nitin writes about technology and how it impacts various industries such as software blog pharma, hospitality, travel, and many other.

To Automate Your Preventive Maintenance Process

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Economic Recession-How CMMS Comes To Your Rescue

Economic Recession-How CMMS Comes To Your Rescue

Impact of Maintenance on Balance Sheet

In an alarming report, the UN’s trade and development body had provided a hint of the possibility of a global recession in 2020. The people, worldwide, feel the heat now with a decline in industrial production, per capita investment & consumption. In such a global scenario, a CMMS is a valuable tool that can demonstrate the degree of impact of maintenance activities on a company’s balance sheet.

Maintenance and post-recession growth

A mere survival during the recession is not praiseworthy. Rather it is high time that businesses rethink pursuing their traditional maintenance management approaches. Companies must be well-positioned to bounce back when the economy recovers and expedite production as soon as possible to shine as before.

Eminent consulting & research firms assert that the companies which combat recession and strike form in a short span are those which spend for out of the box approaches that serve as an alternative to conventional practices. For this strategy to be successful, maintenance has to be a part & parcel of it. Investing in maintenance ensures the production cycle is ready without any hidden delays & potential failures. Better planning is possible only when the health of assets and facilities are well maintained in a good shape. Planning is very essential for any company to make their way out of recession.

Productivity during recession

When the sales drives fail to bring in expected profits companies must turn to minimizing operational costs. For maximum cost efficiency the management must have great insights on the overall maintenance activities. The data on maintenance must be easily traceable and available at the click of a mouse. The best maintenance strategy is automation of work orders and the industries are steadily shifting towards digital transformation of maintenance realm of their businesses.

Apart from productivity concerns during recession, you’ll also be required to maintain your reputation and uphold the safety of workforce. With a good CMMS, in place, it will automate the preventive maintenance schedules. The schedules can, in turn, be broken down into tasks and checklists. These checklists appear right in front of the concerned people while discharging tasks that need special caution and protection.

A capable CMMS will also shield you against any potential legal risks that may arise due to non-compliance of government standards by establishing an effective procedure for work orders and schedules with reminders & escalations so that you never miss out anything you need to pay attention to, on time!

 

To Automate Your Preventive Maintenance Process

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Management System for Free

How Do Faster Service Improve HVAC  Business?

How Do Faster Service Improve HVAC Business?

How Do Faster Service Improve HVAC Business

Obviously Flight…

Because flight is a comfortable and fastest mode of travel….

Similarly everyone will like to have faster method to reach goals. As a customer you look for a faster service in any organizations, especially in HVAC service Industry. The difference between organizations lies between one thing – having loyal customer and those who struggle to retain customers.

Lot of surveys portray that faster delivery of service is as important as the quality of service. The faster service will enhance customer satisfaction , The customers will associate their good customer service experience with the quick resolution of their issue.The customer satisfaction will increase reputation of the company. Companies that are able to produce their products on a reliable schedule or offer reliable services find themselves acquiring very good reputations. Businesses live and die based on their reputations and anything HVAC service companies can do to enhance their reputations is something they should at least consider. While not all reputation boosting moves are worth taking, complete automated cloud CMMS software yields so many benefits in so many areas at so little cost that it is clearly an intelligent strategy for HVAC service companies to adopt.

Companies that neglect their equipment and ignore their reputations may temporarily prosper in the short run, but ultimately they will be displaced by reliable companies with excellent reputations.

Only companies that work on cultivating long-term positive relationships with customers have a good chance of surviving in an increasingly competitive marketplace. Although television and newspaper advertisements certainly have their place, nothing advertises a company better than word of mouth. Building up loyal customers willing to engage in word of mouth advertising is an essential move if companies are to have any chance of achieving long-term success.

Innomaint CMMS software will enhance your company reputation with unique and added advantages.

  • It helps to avoid human error and have effective customer handling.

For instance, the customer can raise the service request with the picture of the equipment to the company. HVAC technician can access the problem immediately and will attend the issue with spare part. The admin of the company can monitor the entire work flow. With this unique feature Turn around time for the problem is minimized.

Workflow image

Geo Location

desktop-map-location

Innomaint software has Geo location benefit. The Geo location will enhance faster service in two ways. It helps the HVAC engineer to find the location of the customer and it will help him reach out to the customer easily. In another way admin can able to track the HVAC service technician GEO location and assign the nearest customer location. This will aid faster service and enhance customer satisfaction. It helps in better tracking and monitoring.

mobile-geo

Mobile Application

CMMS Mobile App is another greatest tool in Innomaint software. The customer can take the photo or video of the problem and send across to the admin. This will enable HVAC service engineer/technician to understand the problem and attend the issue with proper preparation. For instance they can plan the estimated spare parts before attending the issue. This will result in faster service and the issue will be attended in one single visit.
mobile-geo-1

Reminders and Escalation

This facility will remind the task to be completed and in case of non completion it will escalate the next level authority. It helps to monitor the customer service , and tracks whether the task is completed in stipulated time. Thus on time customer service is maintained.

Reminders are set to notify responsible users for any upcoming planned activities like PM, spare parts replacements, contract renewal and so on to ensure the compliance and maintenance process are adhered.

Escalations are defined to alert the decision makers or responsible users for dates that are past due; generally, you can setup escalation for SLA violations, expiration of any contracts or compliances.

 

To Automate Your Preventive Maintenance Process

Try Innomaint Equipment Maintenance
Management System for Free

How Innomaint Cloud CMMS Can Help to Outperform Your Existing Manual Tracking of Preventive Maintenance

How Innomaint Cloud CMMS Can Help to Outperform Your Existing Manual Tracking of Preventive Maintenance

Preventive Maintenance

How Innomaint Cloud CMMS Can Help to Outperform Your Existing Manual Tracking of Preventive Maintenance

Still using spreadsheets to stay on top of preventive maintenance, work orders, your equipment and spare parts. Guess what? You’re not alone.

Based on our analysis around 45% of the industries are still using manual methods to track preventive maintenance and work order manual methods such us excel sheets or even paper based manual maintenance methods.

Our analytics result shows 75% of the people are searching for a Cloud CMMS system to simplify and automate their current maintenance process and 90% of the decision makers are researching on Cloud CMMS to increase efficiency, tracking and managing work orders, preventive maintenance effectively.

Sounds familiar ?

Here are some facts to enlighten you how Innomaint can outperform spreadsheets for tracking preventive maintenance, work orders, and more.

Cloud CMMS software outperforms spreadsheets or any other manual process by;
  • Automating and improving preventive maintenance
  • Simplifying tracking of work orders and repair history
  • Automating email alerts, and reminders
  • Improving responsiveness for tenants and customers
  • Faster service using mobile application and instant notifications

To Automate Your Preventive Maintenance Process

Try Innomaint Equipment Maintenance
Management System for Free

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