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Cutting Maintenance Costs and Improving Efficiency: Envirosystems Inc. Case Study

Envirosystems Inc. Logo

Paul Beauchamp, Regional Maintenance Manager for the Canada division of Envirosystems Inc., has a simple phrase to sum up the value of ManagerPlus to his operation:

“Collect data once, use it many times.”

Beauchamp is responsible for a wide variety of assets–including a fleet of 840 vehicles–that must be maintained properly and kept compliant with regulations. Asset reliability is critical for Envirosystems to achieve their central mission: to clean up hazardous wastes and chemicals for a range of heavy industries, including oil and gas, and government entities.

“For us, the main purpose of ManagerPlus is about being able to determine what we own and where it is. We need to be able to pull work history on trucks and say, ‘this truck was used for this many hours and it cost us this,’” Beauchamp said.

Within his first year of implementing ManagerPlus, Beauchamp has already seen his maintenance costs reduced: tow truck bills have been virtually eliminated because he’s more on top of preventive maintenance. He can now easily monitor critical data on costs and asset location, helping him ensure that he’s sending the right vehicle to the right job, and determine which vehicles require DOT inspections and which don’t. 

Check out our full case study on Envirosystems Inc. to learn more about how ManagerPlus helps Beauchamp run a better maintenance operation.

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How to Create Maintenance Log Types

It’s pretty unusual for a maintenance department to track just one type of equipment. And even on the rare occasions when they do, they still have to track different makes, models, etc. (think about a fleet of vehicles, for instance).

This is why ManagerPlus allows you to set up different “Log Types” for different types of assets. For instance, you can set up miles as a maintenance log type for your vehicles, and create a log to track hours for your forklifts. That way, when you create a work order for a vehicle, only the maintenance log for miles will appear (rather than both hours and miles, which could lead to data entry errors and confusion).

Before I walk through the steps of setting up a log type, let’s define a few of ManagerPlus’s maintenance log related terms you’ll need to understand first.

Metered Log: this is a log taken from an odometer or other type of meter. Each log value you enter replaces the previous entry (each entry is tracked separately, so you can always go back and see each submission, nothing is erased or over-written). Meters can be set as “Descending” meaning they begin with a higher value and drop lower with each log entry (this way the system knows whether to expect a lower or higher value for each subsequent log entry).

Allow Meter Reset: Turning on this option will ‘save your place’ in the event that a meter is reset or replaced. For example, if you’ve been recording miles for a given vehicle and have to replace the odometer, this option will save your place and add subsequent log values to the last reading from the odometer before it was replaced.

Calculated Log: this type is dependent on another log – it will automatically, with no additional entry, take each log entry and calculate an average, max, min, or sum for a period.  Calculating the “average temperature over 30 days” or “total weekly hours” would be examples of these types of logs.

Uses Log Warnings: you will want to turn this option on if you are concerned about data entry errors. If, say, a log value of 2,250 is entered when the previous log entry was 20,000, the system will create a pop up alert and highlight the entry so that you can further review it and make any corrections that may be necessary. Continue reading

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The Importance of Configurability in Maintenance Software

 

Asset settings_custom fields

ManagerPlus offers customization options for each module. This example is taken from the Assets Module.

This week, American Machinist ran an article titled “Why Configurability Matters for Manufacturing Enterprise Software” (form fill required). In it, author Katie Hilyar details the importance of flexibility in enterprise software solutions, citing the substantial differences between the processes that companies of different sizes use to meet their objectives.

At the conclusion of the article, Hilyar outlines the following set of criteria for determining whether a particular enterprise-level software is sufficiently configurable:

– “Ability to extend your application with new functionality (e.g. business processes) not just changing the presentation of existing functions.”

– “No requirement to write or maintain software code – this is one of the key hallmarks of configuration vs. customization.”

– “Drag-and-drop modeling and design tools to rapidly define your processes.”

– “Built-in workflow automation (BPM) to save you time and improve productivity.”

It’s not often that you see a broad concept like configurability addressed in such specific terms, so we thought it might be interesting to assess ManagerPlus maintenance software solutions using these criteria to see how we stack up.

Here’s what we found: Continue reading

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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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