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Implementing Condition Based Maintenance with ManagerPlus

Crysal ball

There is no crystal ball for maintenance. CBM might be the next best thing.

When companies approach ManagerPlus about streamlining their maintenance operations, the conversation often centers around preventive maintenance. In general, companies want to find a better way to track all of their PM schedules in order to stay ahead on their work and keep their vehicles, facilities, and equipment in optimal condition.

ManagerPlus is, of course, the premier solution available to handle all of your PM schedules (just check out our rave reviews), but what about companies that approach maintenance differently?

According to Maintenance and Reliability Best Practices, there is an approach to maintenance that can save 7-15% over traditional preventive maintenance alone. The savings are even more jaw-dropping for companies that do not already have a robust PM program in place, topping 40% overall, with up to 40% less downtime and a corresponding increase in production of up to 25%.

So how are companies achieving such outstanding levels of optimization? The answer is Condition Based Maintenance (CBM). Continue reading

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CMMS ROI Calculator: How Much Can You Save?

When companies approach us looking for ways to streamline and optimize their maintenance operations, one of the first questions we typically get asked is: what’s the return on investment for maintenance software?

The answers can vary widely depending on the industry a company serves, the types of assets they track, and the company’s primary motivation for implementing a maintenance software solution like ManagerPlus. For some companies, the primary savings will come in the form of less time spent on administrative/paperwork, for others it might involve staying ahead on inspections and avoiding regulatory fines.

For manufacturers, however, ROI is best expressed in terms of down time. The good folks over at Software Advice have come up with a nifty calculator to help you see what you might be able to save by implementing a CMMS system. Plug in your company’s numbers and let us know what you find in the comments section!

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ManagerPlus Featured in Better Buys

BetterBuys logo

ManagerPlus is currently featured in BetterBuys’ “The Definitive Guide to CMMS” publication. Highlights from our case studies on Gas Field Specialists and Doyon Utilities is given top billing in the CMMS Use-Cases section. Be sure to check it out, and if you haven’t already, head over to the customers section of our site to download the full case studies!

Check out the BetterBuys article here: https://www.betterbuys.com/cmms/definitive-guide-cmms/cmms-use-cases/

 

 

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OEE: Using Maintenance to Achieve Higher Product Quality

Conveyor Belt

We’ve finally arrived at the third leg of the Overall Equipment Effectiveness (OEE) journey: product/output quality. At this point, if we’ve been calculating the first two components of OEE correctly, we should have accurate measures of equipment availability and the performance of that equipment when it’s operating, which is typically expressed in terms of total output.

By themselves, the first two measures of OEE provide important insight into the impact of your maintenance operations on the overall performance of the company. But they are incomplete without an understanding of product/output quality, which plays a major role in customer satisfaction, revenues, etc.

In OEE, quality is calculated as:

Quality
 = Good Pieces / Total Pieces

Continue reading

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OEE: The Role of Maintenance in Equipment Performance

In our first installment on Overall Equipment Effectiveness (OEE), we looked at how you calculate the availability metric (Availability = Operating Time / Planned Production Time) using data from your CMMS system.

In this installment, we’ll take a look at the next component of OEE: Performance, which is calculated as:

Performance = (Operating Time/ Total Pieces)/ Ideal Cycle Time

Ideal Cycle Time, sometimes referred to as Nameplate Capacity, Theoretical Cycle Time, or Design Cycle Time, is basically just a measure of what a given piece of equipment should be capable of producing under ideal circumstances within a given timeframe.

In manufacturing settings, this is usually measured by throughput—how many parts/pieces a machine produces. In other industries, such as construction, this can be somewhat more difficult to measure, but virtually any measure of output/productivity is workable.

In ManagerPlus, throughput (or cycle counts, in our example) can be easily set up as a log value, which can then be set to trigger a work order automatically if output falls outside of the acceptable range.

First, open ManagerPlus and click on the “Logs” module (1). Within the Logs module, click on the gear icon (2) in the upper left hand corner of the tab, select “Log Types” and click “Edit Lookup” (3) in the Log Settings window.

Log Type Creation_1 Continue reading

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Safety First: Reducing the Risk of Falls and Injuries in the Workplace

cherry picker for guest blog_DM Civil Contractors

This week’s guest blog comes from Jayde Ferguson of DM Civil Contractors.

The construction and mining industry is easily one of the most dangerous when it comes to falls and injuries in the workplace. Each year, thousands are injured on the job and reducing this occurrence of potential risks is a consistently high priority of safety and health professionals all over the country.

Just in Australia alone, recent health and safety statistics reveal a total of 117,815 number of serious claims reported. Muscular stress while lifting, carrying or putting down objects was the top risk, with falls on the same level and falls from a height following closely behind. According to the US Department of Labour, slips trips and falls make up the majority of the general industry accident too, which accounts for about 25% of all reported injury claims in the year.

Thus, it’s safe to say measures need to be taken to ensure the safety of all workers. Whether it’s a momentary lapse of distraction or not taking the right healthy and safety precautions – we check out the importance of putting safety first to help reduce falls and injuries in the workplace.

1. The Importance of Regular Machine Maintenance

To keep work equipment safe and reliable, it’s imperative regular machine maintenance is done. Schedules should be in place to prompt relevant staff to ensure equipment is tested and checked to avoid potential accidents and dangerous situations. According to the European statistics on accidents at work, it’s estimated that around 15-20% of accidents are related to maintenance operations, with around 10% of these leading to fatal incidents. Continue reading

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Know Your Reports: The Basics

The first phase in any successful rollout of ManagerPlus is to run all work orders, logs, PM schedules, inspections, and other primary maintenance tasks through the system.

Once the transition is complete and everyone is using the system to track, schedule and document their work, it’s usually not long before our clients start diving into our Reports Module to gain detailed insight into their data.

Depending on the edition, ManagerPlus offers anywhere from 23 to 84 ready-made reports that provide a wealth of insight into data on assets, work orders, inventory, logs, and much more. Each offer different filtering and configuration options to help you zero-in on the information you need (not to mention the full customization available through the add-on ReportingPlus Module).

With all of these options, it can be difficult to know where to start, so we’ve decided to launch a new blog series: Know Your Reports. This first installment is designed to get you familiar with the basics, so let’s get started.

+ Printing the List View.  Yes, I know I just got done talking up the benefits of our reporting options, but sometimes everything you need to see is right there in front of you in the module list view; all you need to do is print it.

Sorting your data in the list view is easy: you can rearrange columns by dragging and dropping the headers, and add additional columns by clicking the asterisk button (1). You can also right click and select “Show List Grouping” (2) which will create a blank area where column headers can be arranged for a variety of data views. If you want to see totals for any of your column headers, you can right click on the column header and select the footer type to show the count, average, min, max, or sum for the full list or individual groups within the list (3).

In the below example we are working in the Work Orders Module, and have dragged the “Status” header into the List Grouping area, followed by “Work Type.” Now we can see a count of all of the completed work orders for the work type “PREVENTIVE” because we have also added a footer that shows the count. In this case, I have also narrowed down what appears in the list by using search criteria (4), filtering the view based on the “Status” and “Work Type” (check out our in-depth guide to custom search criteria here).

Work order list view 1

Continue reading

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OEE: One Metric That Can Spell Success or Failure for Your Company

forklift2

In business terms, there may be no maintenance-related metric more important than Overall Equipment Effectiveness (OEE).

By accounting for availability, performance, and quality, OEE provides one of the quickest ways to assess the role of maintenance in the overall health of your company. Yet many companies either neglect to track it, or calculate it using incomplete/inaccurate data gathered using outdated paper records and spreadsheets.

World-class companies, by contrast, use CMMS solutions to track detailed information on their equipment and watch their OEE numbers carefully to target areas for improvement. These companies maintain upwards of 90% equipment availability, performance rates of 95% or more, and overall quality of 99% for an OEE greater than or equal to 85%.

So how do they achieve this level of excellence? First, let’s quickly review how OEE and each of its components are calculated:

Availability = Run Time/Total Time (accounts for Down Time losses)

Performance = Total Count/Target Counter (accounts for Speed losses)

Quality = Good Count/Total Count (accounts for Quality losses)

OEE = Availability x Performance x Quality

In order to put these calculations to proper use, world-class companies will define several specific timespans (work shifts, for instance) and calculate these OEE measures for each in order to compare them. In this week’s blog, we’ll focus on availability to see how you can drill into this metric and improve it.

+ Availability

Availability is the foundation of all OEE calculations because it is a straightforward measure of downtime. When it comes to improving OEE, availability is therefore the best place to start.

There are two key factors involved in availability: machine breakdowns and machine adjustments/setups. Continue reading

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How Much Preventive Maintenance Should You Be Doing?

calendar

When companies come to ManagerPlus looking for our maintenance software solutions and expertise, it’s not because they aren’t familiar with preventive maintenance. The vast majority are already performing routine oil changes, replacing HVAC filters, lubricating heavy machinery, performing safety inspections, etc.

In most cases, what they need is for us to assist them in performing these services more efficiently–and we’re extremely effective at helping them accomplish this. So much so, in fact, that they’re often faced with a new dilemma: they now have spare resources and capacity that could be used to perform more advanced forms of preventive maintenance, but they’re not sure if doing so would yield additional benefits.

In other words, we’re able to help them make it so easy to do the preventive maintenance they’ve always been doing, they now have to ask whether they should do more, and whether there is such a thing as too much.

So…is there?

The answer is: it depends, but generally speaking, there’s no such thing as too much preventive maintenance if you’re doing it properly.

According to “Maintenance and Reliability Best Practices” by Ramesh Gulati, companies that run “Best Practice Benchmark” operations schedule between 10-40% of their maintenance work. World class organizations, on the other hand, schedule upwards of 85% of their overall maintenance workload.

The thinking here is that, by proactively scheduling as much of their maintenance work as possible, these companies are able to maximize equipment up-time, utilization rates, and resale value. This makes sense–most authoritative sources suggest that preventive maintenance can be up to 20 times more cost effective than run to failure maintenance.

With ManagerPlus, it’s easy to determine how much of your work is scheduled versus unscheduled. The quickest way to find this information is to run the “Work Order Summary” report in the Reports Module (in our Enterprise Desktop product). This will show a quick count of the number of work orders associated with scheduled work as well as the number that were associated with unscheduled work. Dividing the number of unscheduled WOs by the total overall (unscheduled plus scheduled) and multiplying the result by 100 will give you the percentage of unscheduled work orders.

In the below example (a partial view of the final page of the Work Order Summary report), we can see the count of Scheduled WOs listed as 32, and the count of Unscheduled WOs listed as 12. If we take the 32 scheduled WOs and divide it by the Total WOs–44 in this case–and then multiply the result by 100, we come up with 72.7%.

Work Order Summary Continue reading

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Are You Spending Too Much on Maintenance Labor? Find Out with One Simple Equation

ABCs of Advanced Maintenance: Schedule Compliance Ratio

In our last installment, we looked at the first key metric you should calculate when evaluating your maintenance operations: Maintenance Cost as a Percent of RAV (Replacement Asset Value). In broad terms, this metric indicates whether you’re spending too much on maintenance.

So let’s suppose you’ve used your maintenance management software to perform this calculation for your company, and discovered that you are, in fact, spending too much on maintenance (or you’re in the benchmark best practice range, but want to become world class). Now what?

It’s time to drill down into different facets of your maintenance operations to zero-in on problem areas. And once again, the data you’re tracking in your maintenance management software will prove invaluable.

Since labor typically tops the list of expenses for any company, it makes sense to look there first if you find that your maintenance costs are too high. The key question is, are you getting the maximum amount for every dollar you’re spending on labor?

Answering this question is straightforward–all you need to do is calculate your Schedule Compliance Ratio using data from your maintenance management software. First you’ll need to find the total number of labor hours that have been allocated on all of your work orders over a given period. In ManagerPlus, all you need to do is go to the Reports Module and select the “Work Order Labor Count” report under the Work Orders section.

Work Order Labor Count_resized 2

Continue reading

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