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.
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Market Forecast for 2021 – 2026 by world’s largest revenue impact company
Facility management(FM) is a set of functions that can enhance the value of specific organizational processes. Markets and Markets, a research firm providing quantified B2B research headquartered in Pune, India, and having an office in the USA currently holding 80% of global Fortune 1000 companies, as clients, has published the results of its laborious forecast. It reveals a promising upcoming silent revolution in the global facility management market. According to the survey, the Facility Management(FM) Market presently valued at 42.2 US$ is projected to grow at a CAGR of 1.6% to reach 76.3 US $ in 2026.
InnoMaint adjudged to be a major vendor in the market
In the painstaking process, Markets & Markets arrived at the profiles of key players cutting across geographic boundaries comprehensively by scrutinizing their features, market rankings, core competencies, global presence, etc. The revenue figures were sourced from annual reports of companies. It had access to the latest financial information of key vendors in the context of FM until 2020-21. It adjudged InnoMaint as a major vendor in both Facility Management Software 2021 and Enterprise Asset Maintenance Software 2021 categories.
Tap into the booming Facility Management market by subscribing to Innomaint which is a one-stop CAFM solution for all your Facility Management needs including
A practicable alternative to traditional approaches paving for effective communication on work orders
Quicker and easier audits on maintenance to identify areas of improvement and training requirements
Ability to catch up with maintenance teams while on the move 24×7 and assign tickets based on the current workload of technicians & quicker dispatch of technicians based on Geo-Fencing
Greater visibility into operations for better technician engagement
Deeper cost-cutting on capital expenditure, utility & service expenditure, etc and much more…
Facility Management Market Forecast – The efforts behind
The need for a Facility Management System is more pronounced over time. The entire globe suffered a 4% decrease in GDP, on average. The effect of the pandemic spillover is felt in countries not hard hit by the pandemic as well. The world economy is expected to recover steadily by the end of 2021 but the process will take longer for U.S, Germany, Italy, England & Russia.
Markets & Markets have defined, described, and forecasted the trend in the Facility Management market by component, size of the organization, industry vertical, deployment mode & region. It analyzed opportunities in the market and outlined the competitive landscape for key stakeholders and market leaders.
The B2B software review firm considered five regions across the globe where the FM market was ruling. They were North America, Asia Pacific, Middle East, Europe, Africa & Latin America. It also took into account the marked impact of the pandemic on the FM market. These regions consist of developed countries with well-established infrastructure, which generates huge demand for facility management solutions.
Markets & Markets perceived growth in trend of outsourcing facility management operations. On the Demand front, it interviewed Chief Executive Officers, Chief Operating Officers of MNC’s etc. On the Supply-side, it interviewed Chief Executive Officers and Co-founders of Key Companies. The research organization consulted FM associations such as
Facility Management Association of Australia
Japan Facility Management Association
Facility Management Association of India (FMAI)
Revolution in Facility Management
The growth of the facility management market can be attributed to several revolutionary technologies and concepts such as cognitive computing, augmented reality, virtual reality, IoT and analytics, robots, etc into facility management solutions.
The proliferation of technology along with intelligent software solutions in businesses is a major driving force to the growth of the facility management market. The fact that IT spending has increased considerably in the last 5 years stands as a testimony to this statement. The future demand in the IT and Telecom vertical would be due to demographic and economic factors.
Digital Solution to Facility Management
A Facility Manager automates and simplifies routine planned preventive maintenance to avert any unexpected failure. He also automates predictive maintenance to keep a check on service expenses and frequency of services. In the event of a breakdown, he rises up to the occasion for coordinating the team efforts to make the communication clear and effective driving and tracking the work orders till completion.
He aligns the workforce for constant knowledge sharing and keeps them up-to-date with technological advancements. He streamlines maintenance by keeping your equipment status and maintenance records in an easy-to-use system.
The more consistent an organization’s day-to-day operations are, then the easier it will be to maximize efficiency and productivity. In turn, these changes can lead to improved customer satisfaction, lower costs, and less waste.
The ray of hope in the long-term outlook for Facility Management
Facility management has been evolving as a thriving business that continues to grow across verticals pushing aside the economic setbacks triggered by the pandemic. Enterprises have started realizing that FM can no more be looked down upon as a set of back-office activities. They are of the notion that their organization can achieve success and steady growth only through the efficient and effective management of complex operational business processes in their facilities.
With the growing receptivity to technological advancements, it is no wonder that Facility Management Solutions are in a high demand in the I.T, Telecom & Health Care Sectors to meet regulatory requirements and sustain critical projects and life saving procedures. Facility Management, these days, has extended its scope to cover numerous business functions and processes and hence the complexity. But the sophistication should come with simplicity to end-users. InnoMaint has modeled its CAFM solution around this core concept to evolve and update itself to meet the challenges of today and tomorrow !
INNOMAINT ADJUDGED THE BEST DIGITAL MAINTENANCE SOLUTION FOR HEALTHCARE INDUSTRY
StartUs Insights, headquartered in Austria, is a reputed and well-known data science company with global footprints. They carry out exhaustive and deep research covering startups & scaleups to enable businesses to identify relevant solutions and technologies swiftly. Now it is easy for Health Care Facilities by just referring to the Top 5 Digital Solutions for Maintenance in Health Care Industry. InnoMaint is one of the hand-picked companies out of 280 service providers in the market.
Moments of crisis
By the time you read this blog post, you would have heard the devastating news of a powerful earthquake striking hard the North American island country Haiti for the second time within 11 years. The quake caused the hospitals to be overwhelmed by thousands of patients in a deplorable state battling for life.
Saves Human Lives
The health care facilities in the country were already struggling to deal with the surge in covid-19 cases. The normal functioning of assets in Health Care facilities is so crucial as the industry deals with human lives and not products, unlike other industries. Moreover, many assets are moved constantly within the facility and the equipments run round the clock.
Keep critical equipments running 24×7
Critical pieces of equipment such as ventilators, dialysis machines, etc call for immediate attention. InnoMaint Health Care CMMS helps you to rise above all maintenance concerns. So proper planning, prioritizing, scheduling, and automation of maintenance tasks is the need of the hour to shield the critical assets from power outages to save precious human lives & prevent unplanned downtime.
Advantage of cloud
Our one-stop modernized maintenance simplifies, standardizes & speeds up service by pulling out the entire service history embedded as QR code or barcode with a simple mobile scan.
InnoMaint provides a premium Cloud-based Maintenance Management solution. Every transaction on maintenance is recorded on servers with very high uptime rates possible to ensure minimum disruption to operations through regular planned preventive maintenance and predictive maintenance increasing their lifespan wiping out any hidden failures beforehand.
In line with anti-covid norms
The CMMS also helps Hospitals by maintaining regulatory compliance and attaining NABH accreditation and ISO certification. This is made possible through an easier audit. World Health Organization (WHO) has formally recommended the usage of CMMS in Hospitals. All anti-covid-19 measures formulated by WHO can be followed & tracked easily using InnoMaint. It is a close fit for Health Care Industries. Useful features such as identification of the current location of assets accurately using RFID tags & reader, Bluetooth reader is underway.
Track asset movement
InnoMaint CMMS is a tight fit for Health Care Facilities & Hospital Biomedical Equipment Management. You can also easily track the movement of assets between various locations of your business upon need. Share resources without any deadlock or disturbance to maintenance cycles. You can view asset swapping history at any time. Your CMMS is your loyal follower as you can carry it wherever you go assigning tickets while on the move and view heat maps as a part of business intelligence.
Touchless scanning with AI enabled mask detection
Maintain the ideal environment in laboratories and scan every visitor to the in-patients who may enter in bulk through various entry points in a fully automated touch-free operation using a thermal sensing camera with higher accuracy levels to keep a check on mask violations as well. Crystal clear photos of potential covid-19 candidates and those who wear masks improperly or do not use one are instantly sent to key stakeholders banning their entry to contain the spread of infection to patients. InnoMaint CMMS also keeps Facility Managers informed of the occupancy status of any ward or room in the facility with intelligent PCM cameras to better enforce social distancing as a part of adherence with Government protocols.
Every service request is responded promptly
Our Multimedia ticketing system apart from simplifying communication helps in a clear and exact portrayal of an issue and maintenance personnel can also use it to their benefit by power cycling the device to its normal mode of functioning and attaching it as a video file for evidence of complete fixes. Manage your inventories smartly by handling all spare requests, dispatch of spares & automate the re-order process upon reaching a minimum so that the facilities never run short of required genuine spares or anti-covid19 kits.
Biomedical Maintenance & Calibration
The accuracy of BioMedical instruments is of immense importance. Maintain the accuracy in measurements of bio-medical types of equipment consistently using exclusive calibration workflow as the importance of accuracy in readings and lab results is well known to the medical fraternity. Prepare emergency maintenance schedules(Ad-Hoc) on the spot for surgeries fixed suddenly or for handling emergency cases arriving at casualty wards with auto-assignment of technicians with due priority level, reminders & escalations, etc.
Embrace Digital Revolution for Maintenance
The Health Care Management System has started realizing the need for a Cloud-based software that can also go deep and proactive into closely examining the highest utility costs such as consumption of electricity and correct any erratic consumption patterns. More and more hospitals have already started using it to streamline maintenance operations, reducing utility costs in a clinic & hospital setting. Keep pace with your competitors by empowering yourself with digital tools that would serve as a savior during critical situations.
5 Key Benefits of Predictive Maintenance in the Manufacturing Industry
Every industry requires maintenance to retain optimum functionality. Conventionally, maintenance was divided into two categories, i.e. Preventative Maintenance and Corrective Maintenance. Preventative maintenance refers to all the standard cautionary measures taken to avert or avoid a disaster. Corrective maintenance is exercised after a problem has occurred with equipment or machinery. Predictive maintenance is a more recent corporate philosophy, which falls somewhere between preventative and corrective maintenance.
Predictive maintenance is a regimen that utilizes data analysis tools and condition-monitoring techniques to detect anomalies and defects in industrial operations before they lead to an adversity. The process can predict possible equipment failure, so you can get it under control prior to experiencing a complete shutdown. Below are the 5 key benefits of employing predictive maintenance in the manufacturing industry:
1. Reduced Equipment Failures and Repair Time
When equipment and machinery is continuously monitored in real time, the rate of unexpected glitches or breakdowns is reduced by at least 50%. The early detection of a mechanical problem or deterioration is vital to sidestep hulking fiascos. Since the issue is recognized before the equipment malfunctions, manufacturers can rescue their business from a dry spell. Repair times are automatically diminished, as the faulty parts of a machine are fixed before the situation escalates. It takes less time to restore equipment that is partially damaged, as compared to something that has fallen apart entirely.
2. Lower Maintenance Costs and Greater Asset Lifetime
Since all the manufacturing equipment is audited on a regular basis and extensive issues are deterred, the overall maintenance costs naturally go down. All the machinery and spare parts are tweaked prior to reaching the risk zone, which greatly increases their life. Faults and errors that are not immediately dealt with turn into a hazard, which is always expensive to get rid of. Industrial assets function to their highest capacity with predictive maintenance, which ultimately boosts the business value.
3. Enhanced Workplace Safety
The manufacturing industry relies on manpower as much as on automated solutions. Workers in contact with faulty equipment are prone to encounter severe accidents. When an employee incurs serious injuries due to a workplace accident, he/she is compensated through worker’s compensation insurance policy purchased by the employer. High frequency of equipment failures in an industry is a major threat to the staff’s health and safety; the employer has to pay in the form of high insurance costs, which translates to substantial business loss.
4. Increased Production
Predictive maintenance saves a business from unforeseen catastrophes that lead to prolonged shut down of operations. Therefore, manufacturers do not have to worry about not being able to retain the demand and supply chain. Since the plant can operate more consistently, there will be a noticeable increase in production. Subsequently, manufacturers can expand business and pursue new leads.
5. Improved ROI
Manufacturers who implement predictive maintenance have witnessed an improvement in ROI (return of investment) of up to 30%. The condition-monitoring techniques and data analysis tools have increased the overall efficiency and efficacy of operations; smaller input yields greater output. An increase in production paired with lower maintenance costs results in bigger profits for the business owners. Enhanced wellness of employees and minimal hiccups in operations further cut down capital costs.
John Adams is a paralegal who writes about widespread legal and social issues. He helps readers overcome challenges and solve many personal problems the smart way, rather than the hard way. He aims to reach out to individuals who are unaware of their legal rights, and make the world a better place.
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How Can Industry 4.0 Solutions Help Plant Maintenance Management in 2021?
Industrial Revolution 4.0
Industry 4.0 solutions are the latest management techniques. They are implementing Artificial Intelligence to absolutely changing the way of data collection and explanation done by the machines. In case some industries are still carrying on the backdated technologies, they will experience the most extensive transformation they haven’t ever experienced. Now enterprises implement advanced solutions where humans and robots can talk with each other; they help the companies make improved decisions, better applications, and excellent customer care.
Modern companies are mainly dependent on machines and automation strategies. But the machines can’t perform as per their standard if they are not appropriately maintained. Properly trained employees develop predictive maintenance policies and enhance the companies’ productivity. The Industrial Internet of Things (IIoT) plays a significant role in this maintenance process. It links a machine to machine and machine to human. Predictive management helps the management locate the faults and take necessary measures to ensure that production can occur without any interruption.
Definition of Industry 4.0 solutions:
Industry 4.0 solutions are the latest maintenance management techniques that are highly effective. It brings a revolution in factory management that can be linked easily with IoT, cloud computing, and cognitive computing required for the plants to become smart ones. It could exchange information smoothly between the departments, sensors, tools, and systems. With the help of gathered collection, the 4.0 maintenance solution can provide a reliable assessment to assist administrators in deciding and deciding strategies for the plants’ smooth running.
Role of predictive maintenance in industry 4.0 solution:
Predictive maintenance plays a crucial role in industry 4.0 solutions. It can reduce maintenance or break downs that are not scheduled by depending on equipment sensor data related to vibration, noise, lubrication, and tolerating temperature. Predictive maintenance can also anticipate the tools that can’t work and are required to be replaced.
Advantages of using InnoMaint’s industry 4.0solutions for plant maintenance management:
Industrial revolution 4.0 solutions offered by InnoMaint can help companies manage their tools and also decide when machines require servicing, repairing, and when they need to be replaced before any interference happens in the production work. Therefore, the administration can accordingly design maintenance plans and also decide the appropriate scheduling for their maintenance. It helps the companies to continue the production activity and prevent any intervention. The significant benefits of using current Industry 4.0 solutions for maintenance management in 2021 are:
It minimizes maintenance expenses.
Make sure the production standard.
Improves the performance of the tools
Optimizing the competency of production
Decreasing the downtime and failure of resources
Enhancing the communication flow within the plant
Increases the coordination between man and automated robots
Advocates for proactive work method and declining the reactive way
Improving the supply-chain management strategies
Increase the longevity of the machines, and therefore, economic returns on all resources are increased automatically.
In recent times pharmaceutical companies also use the Industrial 4.0 solutions for managing their wide product range. It helps them to improve production as there are advanced manufacturing tools. Any Indian pharmaceutical company, Oil & Gas company, Manufacturing plant etc can implement these solutions for managing plant maintenance efficiently.
About an author:
Nitin Gupta is a voracious reader and an even passionate writer. Having worked with numerous field Pharmaceutical company in india 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 the various industries such as pharma, hospitality, travel, and many others as well.
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