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

Try Innomaint Equipment Maintenance
Management System for Free

Necessary Features for Maintenance Software to Overcome Challenges posed by COVID-19

Necessary Features for Maintenance Software to Overcome Challenges posed by COVID-19

Necessary Features for Maintenance Software to Overcome Challenges posed by COVID-19

The changes that this COVID-19 blockade will set in motion in every sector are going to be so intense that at this point it’s impossible to even predict them. Especially the industrial sector will see industrialists persevering in the name of getting more productivity on their plate every day.

Exploring new options for facilities management is something every name in the game will do in order to get a headstart from the competitors. As the gears will start to turn again, we’ll see more facility managers adopting facility maintenance software even if it comes at the price of taking another hit at the balance sheet which already has suffered enough.

For ensuring that the resources are used as efficiently as they could be, facility maintenance software must have some key features:

1. Properly Detailed Work Orders:

Another feature that is critical to have in your facility maintenance software is the ability to include more information in work orders. In primitive management systems, work orders used to carry less information which led to communication gaps and hence diminished efficiency.

But now, CMMS software packages have the ability to include minute details like detailed instructions, step-to-step checklists, manuals and schematics, tools required, site patterns, and work order histories.

Due to this standardization of instruction, dealing with a specific problem will be the same throughout the facility and not differ like before. Also, newer members will get to learn more swiftly. This learning will be a requirement for technicians once all the facilities start to function again after lockdowns due to COVID-19 end.

Also with slowed and strained supply chains, inventory management becomes more crucial than ever. Through efficient CMMS software, you can manage your inventory and make the best out of it even during these hard times of impeded supply chains.

2. Preventing Problems Preventive Maintenance:

It’s not a new idea that preventing a problem always takes less than fixing it. A CMMS software will be considered incomplete without the feature of preventive maintenance programs.

It makes the life of the facility manager easier by slashing unpredictability of having to maintain the facility when it fails any time by its choice. It makes operations predictable and orderly.

Due to being less problem-prone than the traditional maintenance preventive maintenance offers improved productivity and longer asset life. Apart from this, it decreases downtime and lets you manage your inventory better.

With the pandemic staring in our faces, the cost-cutting will happen first from maintenance departments before other departments are even touched. So, with fewer resources a CMMS software with a reliable preventive maintenance program will save the day.

3. Accessible Threat Request Portals:

The traditional methods of threat reporting are either the way that facilities keep deteriorating until the problems are too big to handle or have a periodic demand of risk-check technicians that engrosses more time and money than it should.

Instead, your maintenance software should have a threat reporting request portal that is accessible to everyone in the facility. This makes the constant demand of technicians go away which saves money and increases uptime. But, extreme care must be taken in the implementation by giving CMMS software training to everyone in the facility.

These portals should also have some necessary data fields while issuing requests for threats so that the data is received correctly and proper work orders can be created to deal with it.

These features must be used in a way that you can identify which request is a priority and which is not. With COVID-19, not only machine and tool damage will be prioritized but health issues and safety tools will also become a priority.

The struggles after COVID-19 won’t be pieces of cake. But, with the right tools and software like a worthwhile CMMS software at your disposal, it will be slightly easier to survive through it.

 

To Automate Your Preventive Maintenance Process

Try Innomaint Equipment Maintenance
Management System for Free

 

About the Author

Nitin is a voracious reader and a passionate writer. Having worked with numerous HR mobile app companies 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 pharma, hospitality, travel, and many others as well.

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