Blog Article
Maintenance Matters: The Surprising Costs of Ignoring It and How CMMS Helps
By Swetha Anusha Goteti
October 1st, 2024
On papers and in meetings, we often see so many quotes dedicated to STANDARDS in manufacturing, such as
"To be competitive, we have to look for every opportunity to improve efficiencies and productivity while increasing quality"
"Manufacturers should embrace lean manufacturing"
"The most dangerous kind of waste is the waste we do not recognize"
"Productivity is being able to do things that you were never able to do before"
But,
in reality, the gap between expectation and reality is often wider than the Grand Canyon.
In the world of manufacturing, the relentless drive to meet production targets often overshadows critical preventive maintenance practices. Recently, I had the opportunity to visit a big industry’s manufacturing unit that operates around the clock, 24/7, without pausing for preventive maintenance. The unit was strewn with waste, including both defective products and general refuse. Given these conditions, it’s easy to imagine the state of the machinery operating in such an environment. The machines were visibly neglected, corroded, and in dire need of maintenance. The company’s rationale for this neglect was straightforward: halting production for maintenance would disrupt their production targets and hinder their scaling turnover.
This scenario is not unique for one particular industry.
Many factories operate under the misconception that production and maintenance are separate entities. There are those who acknowledge the importance of maintenance but defer it due to production pressures, and there are those who outright dismiss its significance.
The Interconnection of Maintenance and Production
The reality is that maintenance and production are inextricably linked. Effective maintenance strategies, including both preventive maintenance and predictive maintenance, are essential for optimizing production efficiency and ensuring the longevity and reliability of equipment.
Here's why:
For companies struggling to balance production targets with essential maintenance, our solution, Bolt CMMS (Computerized Maintenance Management System), offers a way to integrate these critical aspects seamlessly.
BOLT CMMS is designed to help organizations establish a robust maintenance system without impacting their production schedules.
With BOLT CMMS, companies can:
Schedule and Track Maintenance Tasks
Monitor Equipment Health in Real-Time: Use predictive maintenance tools to keep track of equipment performance, predicting issues before they lead to breakdowns.
Ensure Compliance and Safety
Optimize Resource Allocation
In addition to maintenance management, BOLT CMMS integrates seamlessly with other critical systems such as MES and inventory management software. These integrations ensure that all your systems work in unison to support both maintenance and production needs.
Integrating maintenance with production is not just a necessity; it is a strategy for achieving higher productivity and better product quality. By adopting systems like BOLT CMMS, companies can overcome the traditional barriers and misconceptions, ensuring that their production processes are both efficient and sustainable.
By sharing my experience here, I hope to shed light on the critical relationship between maintenance and production, urging companies to rethink their strategies for the betterment of their operations and workforce.
Feel free to reach out to learn more about how BOLT CMMS can transform your maintenance practices and boost your production efficiency. Let's work together to build a more resilient and productive manufacturing environment.
"To be competitive, we have to look for every opportunity to improve efficiencies and productivity while increasing quality"
"Manufacturers should embrace lean manufacturing"
"The most dangerous kind of waste is the waste we do not recognize"
"Productivity is being able to do things that you were never able to do before"
But,
in reality, the gap between expectation and reality is often wider than the Grand Canyon.
In the world of manufacturing, the relentless drive to meet production targets often overshadows critical preventive maintenance practices. Recently, I had the opportunity to visit a big industry’s manufacturing unit that operates around the clock, 24/7, without pausing for preventive maintenance. The unit was strewn with waste, including both defective products and general refuse. Given these conditions, it’s easy to imagine the state of the machinery operating in such an environment. The machines were visibly neglected, corroded, and in dire need of maintenance. The company’s rationale for this neglect was straightforward: halting production for maintenance would disrupt their production targets and hinder their scaling turnover.
This scenario is not unique for one particular industry.
Many factories operate under the misconception that production and maintenance are separate entities. There are those who acknowledge the importance of maintenance but defer it due to production pressures, and there are those who outright dismiss its significance.
The Interconnection of Maintenance and Production
The reality is that maintenance and production are inextricably linked. Effective maintenance strategies, including both preventive maintenance and predictive maintenance, are essential for optimizing production efficiency and ensuring the longevity and reliability of equipment.
Here's why:
- Preventive Maintenance Minimizes Downtime: Regularly scheduled preventive maintenance, a core feature of any maintenance management software, can prevent unexpected breakdowns, which cause significant production delays. By addressing potential issues before they escalate, factories can maintain a smoother, more reliable production schedule.
- Enhanced Equipment Lifespan: Consistent maintenance extends the life of machinery, reducing the frequency and cost of replacements. This not only saves money but also ensures that production remains consistent without the disruptions caused by equipment failure.
- Improved Safety Standards: Maintenance is crucial for maintaining safe working conditions. In environments that are already hazardous, like the hot and dusty plant mentioned above, neglecting maintenance can lead to dangerous accidents, putting workers at risk and potentially leading to costly shutdowns.
- Quality Control: Well-maintained machines produce higher-quality products. Inconsistent maintenance can lead to defects and variations in product quality, which can harm a company’s reputation and lead to waste.
- Operational Efficiency: A well-maintained machine operates more efficiently, consuming less energy and operating at optimal performance levels. This efficiency translates directly into increased production output and reduced operational costs.
For companies struggling to balance production targets with essential maintenance, our solution, Bolt CMMS (Computerized Maintenance Management System), offers a way to integrate these critical aspects seamlessly.
BOLT CMMS is designed to help organizations establish a robust maintenance system without impacting their production schedules.
With BOLT CMMS, companies can:
Schedule and Track Maintenance Tasks
Monitor Equipment Health in Real-Time: Use predictive maintenance tools to keep track of equipment performance, predicting issues before they lead to breakdowns.
Ensure Compliance and Safety
Optimize Resource Allocation
In addition to maintenance management, BOLT CMMS integrates seamlessly with other critical systems such as MES and inventory management software. These integrations ensure that all your systems work in unison to support both maintenance and production needs.
Integrating maintenance with production is not just a necessity; it is a strategy for achieving higher productivity and better product quality. By adopting systems like BOLT CMMS, companies can overcome the traditional barriers and misconceptions, ensuring that their production processes are both efficient and sustainable.
By sharing my experience here, I hope to shed light on the critical relationship between maintenance and production, urging companies to rethink their strategies for the betterment of their operations and workforce.
Feel free to reach out to learn more about how BOLT CMMS can transform your maintenance practices and boost your production efficiency. Let's work together to build a more resilient and productive manufacturing environment.