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CMMS
CMMS for Preventive Maintenance
Introduction Conventional concepts such as the one that suggested intervention for repair only when a failure occurs have proven their validity in the past, but have been supplanted for several years by new techniques and systems, primarily that known as preventive maintenance. The possibility of applying maintenance management to any type of activity, also […]
Introduction
Conventional concepts such as the one that suggested intervention for repair only when a failure occurs have proven their validity in the past, but have been supplanted for several years by new techniques and systems, primarily that known as preventive maintenance. The possibility of applying maintenance management to any type of activity, also thanks to the use of maintenance management software (CMMS), has allowed its diffusion among an increasing number of companies aware that if they want to maintain their competitiveness, it is necessary to avoid excessively high costs caused by productivity losses, low levels quality, downtime and therefore, in other words, loss of profit.
What Does CMMS Software Do and How Does it Work?
The CMMS is a software capable of containing all the maintenance information: from the technical database to the asset sheets, through maintenance plans, requests for technical intervention and work orders. It also allows you to manage all the documentation, the history of interventions and work reports, the spare parts in the warehouse, as well as of course the technicians and suppliers.
Thanks to all this information, it is able not only to help you optimize maintenance processes, but also to provide all the data necessary for a detailed analysis of them, monitoring times, costs and performance thanks to business intelligence systems that analyze the data for you, creating personalized and incredibly detailed reports.
The best CMMS software is also able to automate a large part of these processes, for example by automatically creating work orders or assigning them, always automatically, to the right personnel, based on the indications you have given to the system.
Let's say for example that you need to plan preventive maintenance interventions based on the working time of a machine. The CMMS is able to generate a new work order every time this time is reached, inform you if spare parts are available in stock, attach the necessary documents and maintenance checklists to ensure that the interventions are carried out in the correct way and finally assign them to the personnel indicated on the basis of the machinery or its location.
This allows you to drastically reduce the costs and management times of your resources, as well as naturally machine downtime, also reducing manual actions and margins of error.
One of the most important features of modern CMMS systems is the ability to use the mobile app.
Thanks to the mobile app, technicians can take the CMMS for company maintenance with them wherever they go in the field. They will be notified via a simple notification (or an email) when they are assigned a work order, they will be able to consult the documentation, record the intervention times, take advantage of the checklists attached to the work order and add the pieces in just a few taps spare parts used on the final report.
This will allow them not only to cut intervention times, but also to automatically record all data and information relating to the work order within the CMMS system. Once the intervention is completed, they will be able to automatically generate the end of work report, create it directly on their phone and send it to the system (as well as by email to the figures involved).
At this point the CMMS system records the data and sorts them within the platform, where they will be available in real time.
Likewise, the maintenance manager will have a complete view of the progress of maintenance operations, will be able to easily monitor, without any additional action, the work orders carried out and those still to be carried out, as well as analyze the recorded data in real time.
What is Preventive Maintenance?
Preventive maintenance is a special type of extraordinary maintenance that is carried out at predetermined intervals or according to the criteria prescribed in maintenance plans, and aims to reduce the probability of failure or deterioration of the functioning of assets or systems.
Definition of Preventive Maintenance
To give the most complete possible definition, preventive maintenance refers to all those activities that allow us to recognize the current functioning of the system, in order to take the necessary measures to slow down its normal degradation.
Objectives of Preventive Maintenance
Preventive maintenance therefore has the main objective of extending the life cycle of assets and limiting machine downtime or, more generally, other corrective maintenance actions, in order to prevent excessive qualitative and quantitative deterioration of production. This goal is achieved through periodic inspections or based on certain metrics chosen by the maintainer, so that necessary but not yet obvious preventive interventions can be implemented before excessive wear or failure becomes apparent.
This type of maintenance includes actions such as cleaning, lubrication, and replacement of plant or asset components.
Types of Preventive Maintenance
Even if it is not entirely precise, in general we could say that any type of intervention that does not belong to the field of corrective maintenance, therefore does not respond to a malfunction, belongs to the category of preventive maintenance. For this reason, there are many types of preventive maintenance and they require different technologies and experiences.
The most common types of preventive maintenance are:
Maintenance in Condition
Periodic Maintenance (Cyclic Preventive Maintenance)
Predictive Maintenance
Preventive Maintenance in Condition
It is a maintenance policy based on meter readings or monitoring of specific pre-determined metrics, recorded and fed into the CMMS system. When the values set in the maintenance software are reached, a work order is automatically generated. A very simple example of this type of maintenance concerns cars: changing tires is a type of condition-based maintenance, as the check is performed based on the kilometers traveled and the condition of the component itself.
Periodic Preventive Maintenance (Cyclic)
Periodic preventive maintenance (or also cyclical maintenance) is a special type of maintenance based on predetermined cycles of use. Cyclic maintenance is a type of planned maintenance, i.e. which is carried out in accordance with the maintenance plan determined on a time basis. Unlike maintenance according to condition, in this case the decisive factor is the time of use of a particular machine or system, the number of trips or mileage. A simple but effective example is the fire extinguishers inside the building, which, due to compliance with regulations, must be inspected at the time intervals prescribed by law. But changing the car's engine belt also belongs to that category, because a certain condition is created, the mileage traveled, with the aim of predicting the occurrence of a failure.
Other Types of Preventive Maintenance
However, among the various types of preventive maintenance there are others that we have not yet mentioned. Some of them are:
Statistical Preventive Maintenance: A type of maintenance planned based on statistical considerations relating to the duration and average life cycle of a component or machine. This type of maintenance, which partly belongs to those mentioned above, is often considered an integral part of periodic (or cyclical) maintenance since it is based on predetermined cycles of use.
Opportunistic Maintenance: Although this particular type of maintenance strategy is not necessarily part of preventive maintenance, the latter greatly favors its occurrence, because often, in cases of corrective maintenance, there is no time or real coordination to take advantage of the incident and the course of action of this type is ongoing. Therefore, it takes advantage of the period of planned shutdown or unavailability of the system to carry out inspections or overall maintenance interventions, in order to optimize times and ensure efficiency.
Preventive Maintenance Management Through Computerized Maintenance Management Software (CMMS)
The rapid evolution of today's market forces all companies to actively engage in order to gain a competitive advantage over the competition. In this context, we have seen how preventive maintenance represents one of the fundamental aspects for achieving this goal.
One of the ways a company can improve the management of maintenance activities involves the use of software solutions that can involve and seamlessly connect the entire organization. For these reasons, more and more companies decide to introduce software solutions with advanced features.
Maintenance management software, commonly referred to as CMMS, an acronym for Computerized Maintenance Management Software, is a tool used by maintenance managers to manage their activities.
Unlike preventive maintenance management that is tracked through generic software, such as classic Excel, using maintenance management software provides maintenance teams with a large amount of notifications and information that is automatically generated when it is expected, thus facilitating the completion of assigned tasks. The above reports not only show updated information about the most problematic parts of the plant or machinery, but also allow you to measure the effectiveness of the operational teams and what to work on to improve the quality of interventions.
None of these goals can be achieved without the use of a maintenance software package.
Today, companies of all sizes, from the smallest ones composed of a few teams, to large multinationals with hundreds or thousands of maintenance workers, use some type of maintenance software. Generally, a CMMS is managed by a maintenance manager and technicians who have access to the system with progressively reduced authority depending on the level of responsibility.
Furthermore, CMMS or more simply maintenance management software is also used by senior management, who use reports generated by financial reporting systems to reduce maintenance costs, identify causes of accidents, measure productivity index and ensure compliance with applicable regulations.
CMMS for Preventive Maintenance
A Computerized Maintenance Management System (CMMS) has the ability to carry out various functions that aid in the smooth execution of preventive maintenance tasks:
With the help of CMMS software, users have the ability to schedule preventive maintenance tasks using predetermined intervals, whether it be time-based (such as monthly or quarterly) or usage-based (after a certain number of operating hours). It is possible to establish recurring maintenance schedules for either individual assets or groups of assets.
The CMMS system allows users to allocate preventive maintenance assignments to designated maintenance technicians or teams. Assignments can be made considering factors such as skill levels, availability, workload, or geographic location, guaranteeing that tasks are carried out by the most suitable personnel.
The generation of work orders is seamlessly facilitated by the CMMS system, which automatically creates them for scheduled preventive maintenance tasks. These work orders encompass comprehensive instructions, checklists, and specifications that guarantee uniformity and adherence to standards during the execution of maintenance activities.
CMMS has the capability to automatically send alerts and notifications to maintenance staff when preventive maintenance tasks are approaching or past their due dates. These reminders can be received through email, SMS, or directly within the CMMS dashboard, ensuring that technicians are reminded to complete their scheduled maintenance activities.
With the help of CMMS, users have the ability to meticulously document their preventive maintenance endeavors, encompassing the completion of tasks, observations made, and any challenges encountered along the way. This comprehensive documentation allows users to record crucial maintenance data, including the date and time of service, labor hours invested, parts utilized, and the overall condition of the equipment. This invaluable information can then be easily referenced and analyzed in the future.
CMMS enables the tracking of asset history, providing a comprehensive record of all preventive maintenance conducted on each individual asset. Users have the ability to retrieve asset maintenance records, review previous maintenance tasks, and monitor maintenance patterns over time in order to evaluate the performance and dependability of the assets.
As part of preventive maintenance, CMMS offers inspection checklists that can be customized to suit specific needs. These checklists allow users to establish inspection criteria, checklist items, and pass/fail criteria, ensuring that assets are thoroughly and consistently inspected.
The integration of predictive maintenance is a feature available in certain advanced CMMS platforms. These platforms have the capability to connect with predictive maintenance technologies like IoT sensors and condition monitoring systems. By gathering and analyzing data in real-time from these sensors, the CMMS can anticipate equipment failures and initiate proactive preventive maintenance measures.
CMMS provides reporting and analysis capabilities to evaluate the effectiveness of preventive maintenance. This includes generating reports and analytics on various performance metrics such as completion rates, adherence to schedules, reduction in downtime, and cost savings. By analyzing this data, users can pinpoint areas that require improvement, optimize maintenance strategies, and showcase the return on investment.
CMMS has the capability to seamlessly integrate with maintenance parts inventory systems, guaranteeing the availability of essential parts and materials for preventive maintenance tasks. This integration allows users to effortlessly generate purchase orders or replenishment requests for the parts needed for scheduled maintenance activities.
The Advantages of CMMS for Preventive Maintenance
Organizations can benefit from various advantages when they choose to implement a Computerized Maintenance Management System (CMMS) for preventive maintenance.
Through the practice of preventive maintenance, organizations can effectively identify and resolve potential problems before they escalate into expensive breakdowns or failures. By taking proactive measures to service equipment and address maintenance requirements, businesses can significantly reduce unplanned downtime and ensure seamless operational continuity.
The longevity of assets can be prolonged through the implementation of regular preventive maintenance practices. By regularly inspecting, servicing, and repairing equipment, machinery, and facilities, organizations can enhance asset performance, minimize deterioration, and fully utilize the lifespan of their assets.
One of the benefits of preventive maintenance is its ability to decrease maintenance expenses by minimizing the necessity for urgent repairs and replacements. By proactively addressing issues and preventing major breakdowns, businesses can avoid expensive periods of inactivity, repairs, and replacement costs, ultimately resulting in substantial savings in the long run.
Regular maintenance and servicing of equipment through preventive measures significantly improves reliability and performance. By minimizing the likelihood of unforeseen malfunctions, operational dependability, productivity, and efficiency are all heightened.
Creating a safer work environment is achieved through regular maintenance inspections and servicing, which play a vital role in identifying and resolving safety hazards and equipment problems. By implementing preventive maintenance measures, the potential for accidents, injuries, and occupational hazards caused by faulty equipment is significantly reduced.
Maintaining compliance with regulations is a crucial aspect of organizational operations. Preventive maintenance plays a vital role in meeting regulatory requirements and adhering to industry standards for equipment safety and maintenance. Through thorough documentation of maintenance activities, inspections, and repairs, organizations can effectively showcase their commitment to compliance and establish a sense of accountability.
Effective inventory management is crucial for organizations to efficiently handle spare parts, materials, and supplies needed for maintenance tasks. Through the implementation of preventive maintenance, organizations can accurately predict maintenance requirements and adjust stock levels accordingly. This proactive approach allows for optimized inventory management, minimizing the occurrence of stockouts and avoiding unnecessary costs associated with excess inventory.
The implementation of preventive maintenance measures results in heightened accessibility of equipment, as it guarantees that assets are adequately maintained and ready for utilization whenever required. By strategically scheduling maintenance activities during planned periods of downtime and non-peak hours, organizations can effectively reduce operational disruptions and optimize the availability of their equipment.
The implementation of preventive maintenance enables organizations to enhance their planning and scheduling of maintenance activities. Through the utilization of CMMS software, which automates maintenance scheduling, monitors asset status, and prioritizes tasks, organizations can achieve optimal allocation of resources, reduce idle time, and enhance overall maintenance efficiency.
The implementation of preventive maintenance generates a wealth of valuable information and insights pertaining to the performance of equipment, maintenance patterns, and metrics of reliability. Through the analysis of this maintenance data, organizations can pinpoint areas for improvement, make informed decisions based on data, and continually enhance their strategies for preventive maintenance.
Conclusion
By utilizing a CMMS to incorporate preventive maintenance, organizations can reap a multitude of benefits. These include minimizing downtime, prolonging the lifespan of assets, saving costs, enhancing reliability and safety, ensuring compliance with regulations, optimizing inventory management, maximizing equipment availability, improving planning and scheduling, and making informed decisions based on data. Through proactive maintenance management, businesses can achieve heightened efficiency, productivity, and a competitive edge in their operations.
CMMS
CMMS for Construction and Building Management
Introduction
CMMS in construction and building management is software designed to centralize and automate maintenance operations. It helps manage assets, schedule preventive maintenance, handle work orders, track inventory, and ensure regulatory compliance. CMMS enhances efficiency, reduces downtime, and contributes to the overall reliability and longevity of construction projects and building facilities.
What is a CMMS?
The acronym CMMS stands for Computerized Maintenance Management System. CMMS software package was designed to manage maintenance practices globally, on a strategic, financial, and operational level. It is today the essential software of the industrial sector. Much more than simple computer programming, it is an assistant for maintenance teams, the cornerstone of industrial efficiency.
Read also 20 benefit of CMMS
Construction and Building Management
Construction and building management involves the planning, coordination, and control of construction projects from conception to completion. These processes are critical for ensuring that a construction project is completed on time, within budget, and to the satisfaction of all stakeholders. Here are some key aspects of construction and building management:
Project Planning
Scope Definition: Clearly defining the project's objectives, requirements, and deliverables.
Budgeting: Estimating costs and creating a budget for the project.
Scheduling: Developing a timeline for the project, including milestones and deadlines.
Design Management
Architectural Design: Collaborating with architects to create detailed plans and specifications.
Engineering Design: Coordinating with engineers for structural, mechanical, and electrical design.
Construction Execution
Site Management: Overseeing day-to-day activities on the construction site.
Quality Control: Ensuring that the construction meets specified standards and regulations.
Safety Management: Implementing and enforcing safety protocols to protect workers and the public.
Cost Control
Monitoring Expenses: Tracking costs throughout the project and making adjustments as necessary.
Change Management: Handling changes to the project scope and assessing their impact on cost and schedule.
Risk Management
Identifying Risks: Anticipating potential issues that could impact the project.
Mitigation Strategies: Developing plans to minimize or address potential risks.
Construction and building management professionals, such as project managers and construction managers, play a crucial role in coordinating these various aspects to ensure a successful and efficient construction process. They must possess a combination of technical knowledge, project management skills, and the ability to collaborate with diverse teams.
What is CMMS in Construction and Building Management?
In the context of construction and building management, a CMMS is a software solution designed to streamline and automate maintenance operations. Here are some key CMMS features and functions in construction and building management:
Asset Management – helps organizations track and manage all their assets, including equipment, machinery, and facilities. It provides detailed information about each asset, including its maintenance history, specifications, and location.
Preventive Maintenance – allows for the scheduling and management of routine maintenance tasks to prevent equipment failures and reduce downtime. It automates the generation of preventive maintenance schedules based on time, usage, or condition.
Work Order Management – Work orders are created, assigned, and tracked within the CMMS. This includes both routine maintenance tasks and reactive maintenance in response to reported issues. Work orders help ensure that maintenance activities are organized and executed efficiently.
Inventory Management – helps organizations manage spare parts and inventory related to maintenance activities. It ensures that necessary supplies are available, reducing delays in maintenance tasks.
Document Management – serves as a centralized repository for manuals, schematics, and other documentation related to equipment and facilities. This makes information easily accessible to maintenance personnel.
Downtime Reduction – Through preventive maintenance and real-time monitoring of equipment health, CMMS helps reduce unexpected downtime by identifying and addressing potential issues before they become critical.
Mobile Accessibility – Many CMMS solutions offer mobile applications, allowing maintenance teams to access information, create work orders, and update asset records from the field, promoting flexibility and responsiveness.
Regulatory Compliance – CMMS assists in maintaining records required for regulatory compliance. It ensures that maintenance activities adhere to industry standards and regulations.
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What are the Challenges in Construction and Building Management?
Construction and building management face a variety of challenges, ranging from planning and execution issues to external factors. Here are some common challenges in construction and building management:
Regulatory Compliance
Cause: Evolving building codes, environmental regulations, and safety standards.
Impact: Delays, increased costs for compliance, and potential legal issues.
Risk Management
Cause: Unforeseen events like natural disasters, economic downturns, or geopolitical issues.
Impact: Project disruptions, increased costs, and safety concerns.
Communication Breakdown
Cause: Ineffective communication among project teams, stakeholders, and contractors.
Impact: Misunderstandings, errors in execution, and delays in decision-making.
Labor Shortages
Cause: Shortages of skilled labor in the construction industry.
Impact: Delays in project timelines, increased labor costs, and potential compromises in work quality.
Material Shortages and Price Fluctuations
Cause: Global supply chain disruptions, market demand, or geopolitical factors.
Impact: Increased costs, delays in procurement, and challenges in maintaining project schedules.
Environmental and Sustainability Concerns
Cause: Increasing emphasis on sustainable construction practices and green building standards.
Impact: Additional planning and compliance requirements, potential increased costs.
Addressing these challenges requires a combination of effective project management, clear communication, risk mitigation strategies, and the ability to adapt to changing circumstances.
How CMMS Can Help to Avoid Challenges in Construction and Building Management?
Computerized Maintenance Management Systems (CMMS) can play a crucial role in improving efficiency, reducing costs, and enhancing overall management in construction and building operations. Here are several ways in which CMMS can benefit construction and building management:
Tracking and Maintenance: CMMS can help manage and track various assets, including equipment, machinery, and facilities, ensuring they are properly maintained and serviced.
Scheduled Maintenance: CMMS allows for the scheduling of routine maintenance tasks, reducing the likelihood of unexpected breakdowns and extending the life of equipment.
Efficient Workflows: CMMS streamlines the creation, assignment, and tracking of work orders, ensuring that maintenance tasks are efficiently managed and completed.
Stock Control: CMMS helps in managing spare parts and inventory, ensuring that the necessary supplies are available when needed and preventing unnecessary downtime.
Expense Monitoring: CMMS can track maintenance costs, helping in budgeting and identifying areas for potential cost savings.
Centralized Information: CMMS serves as a centralized repository for manuals, schematics, and other documentation, making information easily accessible for maintenance teams.
Record Keeping: CMMS assists in maintaining records required for regulatory compliance, ensuring that the building or construction site adheres to industry standards and regulations.
Proactive Maintenance: With preventive maintenance schedules and real-time monitoring, CMMS helps reduce unexpected downtime by identifying and addressing potential issues before they escalate.
Remote Management: Many modern CMMS solutions offer mobile applications, enabling maintenance teams to access information, create work orders, and track progress remotely, enhancing flexibility.
Conclusion
By incorporating CMMS into construction and building management practices, organizations can optimize maintenance processes, reduce operational costs, and improve the overall reliability and lifespan of assets. The proactive approach facilitated by CMMS contributes to a more streamlined and efficient construction and building management lifecycle.
CMMS
How to Use CMMS for Root Cause Analysis
Introduction
Root cause analysis (RCA) and detailed equipment records in a computerized maintenance management system (CMMS) can help solve difficult equipment and process problems.
Many companies struggle with RCA issues on equipment and processes. Many maintenance departments are so busy fighting fires that they have little time to investigate the root cause of equipment malfunctions or process failures.
You often hear maintenance people say "That machine" or "that part" broke again, and then they go out to fix it. Usually, the problem has happened so often that they know what to do and can usually fix it quickly. Very few people take the time, or have the time, to dig into the problem and see what’s really going on.
What is a Root Cause Analysis?
Root Cause Analysis (RCA) is a systematic process to identify the underlying causes of problems or issues within a system, process, or situation. The goal of RCA is to go beyond addressing the immediate symptoms and instead focus on understanding and addressing the root causes to prevent the recurrence of problems.
The process typically involves several steps:
Problem Identification: Clearly define the problem or issue that needs to be addressed. This could be a quality problem, a safety incident, a process failure, or any other issue.
Data Collection: Gather relevant data and information about the problem. This may involve reviewing documents, conducting interviews, analyzing records, and collecting data from various sources.
Cause and Effect Analysis: Use tools such as Fishbone Diagrams (Ishikawa diagrams) or Fault Tree Analysis to map out the possible causes and their relationships. This helps in visually organizing and understanding the factors contributing to the problem.
Verify Root Causes: Validate the identified root causes through data analysis, expert input, or other means to ensure accuracy and reliability.
Implementation of Solutions: Put the recommended solutions into action. This may involve changes to processes, procedures, training programs, or other aspects of the system.
Monitor and Evaluate: Track the implementation of solutions and monitor their effectiveness over time. Evaluate the impact of the changes to ensure that the problem is indeed resolved and that there are no unintended consequences.
How does RCA Work?
RCA is based on the principle that all events are causally related.
Simply responding to the effects of adverse events is not always enough. To completely solve the problem, we must trace the events back to the original "falling dominoes."
Simply put, root cause analysis helps you understand what happened, how it happened, and why it happened. The process is based on the "Three R's":
Recognize: Keep in mind that if an asset fails, you may not be able to determine the true cause of the event through simple observation. What you are observing is just a symptom. Determine the real cause of the problem to prevent it from happening again in the future.
Remedy: Once you determine the root cause of the problem, take corrective action. Then monitor the system to see if the problem recurs. If the problem reoccurs, your team may confuse part of the cause with the root cause. In this case, go back to the drawing board and do a more thorough RCA.
Repeat: Finally, replicate the working solution in other locations using similar assets. This prevents the same error from occurring in other areas of the system.
Importance of Root Cause Analysis
Root Cause Analysis (RCA) is important for several reasons across various industries. Here are some key aspects that highlight its significance:
Preventing Recurrence: The primary goal of RCA is to identify and address the root causes of problems or issues. By doing so, organizations can implement corrective actions that not only resolve the current problem but also prevent its recurrence. This proactive approach contributes to long-term improvement and stability.
Cost Reduction: Addressing root causes helps in eliminating inefficiencies and reducing the costs associated with recurring problems. Instead of repeatedly dealing with the symptoms of an issue, organizations can invest resources in implementing long-term solutions, leading to cost savings over time.
Enhancing Quality and Reliability: Understanding the root causes of defects or failures allows organizations to improve the quality and reliability of their products or services. This is particularly crucial in industries where safety, precision, and consistency are paramount, such as healthcare, aviation, and manufacturing.
Risk Management: RCA contributes to effective risk management by identifying and mitigating potential risks before they escalate into significant problems. This proactive approach helps organizations avoid crises and enhances their overall resilience.
Customer Satisfaction: Resolving issues at their root enhances the quality and reliability of products and services, leading to increased customer satisfaction. Satisfied customers are more likely to remain loyal and recommend the organization to others.
In summary, Root Cause Analysis is crucial for organizations aiming to improve their processes, products, and overall performance. It provides a structured method for identifying and addressing the underlying causes of problems, leading to sustained improvements and increased organizational effectiveness.
When to Perform Root Cause Analysis?
Root Cause Analysis (RCA) is a valuable tool that can be applied in various situations to identify and address the underlying causes of problems. Here are some common scenarios in which performing RCA is particularly beneficial:
Recurring Issues: When a problem or issue continues to recur, it indicates that addressing only the symptoms is not sufficient. RCA can help in uncovering the root causes and implementing corrective actions to prevent the issue from happening again.
Significant Failures or Incidents: Following major equipment failures, accidents, or incidents, conducting an RCA is crucial. Understanding the root causes of significant events helps prevent their recurrence and enhances overall safety and reliability.
Quality Issues: If there are consistent quality problems in products or services, RCA can be employed to identify the factors leading to these issues. This is especially important in industries where product quality is a critical factor.
Safety Incidents: In situations where safety is compromised, conducting an RCA is essential. This applies to industries such as manufacturing, construction, and healthcare, where safety incidents can have severe consequences.
Process Failures: When processes are not meeting performance expectations or are consistently failing, RCA can help uncover the reasons behind these failures. This is crucial for improving efficiency and productivity.
Customer Complaints: If there is a pattern of customer complaints, performing an RCA can help identify the root causes of dissatisfaction. Addressing these causes can improve customer satisfaction and prevent future complaints.
Unexpected Variations: In manufacturing or other processes where consistency is crucial, unexpected variations or deviations may occur. RCA can help identify the reasons behind these variations and implement corrective actions.
It's important to note that RCA is a versatile tool that can be applied in various industries and contexts. The decision to perform RCA should be based on the significance of the problem, the potential impact on operations, safety considerations, and the organization's commitment to continuous improvement.
How to Conduct Root Cause Analysis in 6 Steps?
Best practices for effective root cause analysis require completing the following steps: defining the problem, collecting data, identifying additional causes, determining the root cause, prioritizing the cause, and implementing a solution.
1. Define the problem
The first step in root cause analysis is to analyze the existing situation. Here, the team identifies the factors that influenced the problem event. The result of this step is a statement that contains the specific problem. A small team is tasked with defining the problem. They can be research assistants who evaluate and analyze situations. The questions that need to be answered at this initial stage are: What is the problem? How does this issue impact customer demand? Etc.
2. Gather data about the problem
A key step in root cause analysis is collecting relevant data about an incident or problem event. Logging all the features and specifications of an event will help you answer questions like: What were the influencing factors? When did it occur? Is this a recurring event? What is the observed effect? Etc.
3. Identify possible causative factors
Creating a sequence of events is important to identify causal factors that may have caused the observed problem or event. The project team responsible for analyzing the problem should create a timeline of events and summarize as many potential causal factors as possible by asking the question "Why?" question. For example, using a cause-and-effect diagram can help visually show the connections between events and allow you to trace root causes.
4. Determine the root cause of the problem
Now is the time to find out as many reasons as possible. The analytics team can use techniques such as 5 Whys analysis, fishbone analysis, or Pareto charts to narrow down the potential causes and key contributing factors to the problem. This phase should involve stakeholders and other relevant teams.
5. Prioritize why
Once the root cause is identified, it needs to be prioritized and addressed accordingly. To determine which cause or challenge needs to be addressed first, the analytics team must assess the impact of that cause – the greater the impact, the higher the priority. Another point to consider when prioritizing root causes is the number of causal factors that arise from a particular challenge – the greater the number of causal factors, the greater the impact of the root cause and the greater the need for immediate resolution.
6. Solutions, suggestions, and implementation
Once the root causes have been identified and prioritized, the next step is to find solutions to the problem and implement them. Brainstorming is a great way to try and develop different possible solution scenarios. Another approach is to survey as many people as possible. Gathering input and implementing solutions requires everyone’s participation. On the one hand, every recommendation is important, but on the other hand, successful implementation is what makes it stick for everyone affected.
What is the Role Of CMMS in Root Cause Analysis?
Computerized Maintenance Management Systems (CMMS) play a significant role in facilitating Root Cause Analysis (RCA) by providing a structured framework for managing and analyzing maintenance-related data. Here are several ways in which WorkTrek CMMS contributes to the RCA process:
Data Collection and Storage: CMMS systems store vast amounts of historical maintenance data, including work orders, equipment failure reports, and maintenance activities. This data serves as a valuable resource for identifying patterns and trends related to equipment failures or performance issues.
Maintenance History Tracking: CMMS keeps a detailed record of maintenance activities, repairs, and replacements over time. This historical maintenance data is essential for RCA, allowing analysts to trace the performance of equipment and identify recurring issues.
Failure Analysis: CMMS tools often include features that help in categorizing and analyzing equipment failures. By using codes or categories, maintenance teams can quickly identify the types and frequencies of failures, which is crucial for identifying potential root causes.
Work Order Tracking: CMMS systems enable the tracking of work orders, providing information on the tasks performed, parts used, and associated costs. This information can be valuable in understanding the effectiveness of past maintenance efforts and identifying areas for improvement.
Equipment Reliability Metrics: CMMS allows organizations to generate reliability metrics and key performance indicators (KPIs) related to equipment performance. Analyzing these metrics can reveal trends and patterns that may indicate underlying issues requiring further investigation through RCA.
Prioritizing Maintenance Activities: CMMS assists in prioritizing maintenance activities based on criticality and historical data. This prioritization ensures that resources are allocated efficiently to address the most significant issues first, contributing to a more effective RCA process.
How to Use CMMS for Root Cause Analysis?
Using a Computerized Maintenance Management System (CMMS) for Root Cause Analysis (RCA) involves leveraging the system's features and capabilities to gather, organize, and analyze maintenance data. Here are steps and considerations for using CMMS in the RCA process:
Capture Detailed Maintenance Data: Ensure that your CMMS is configured to capture comprehensive maintenance data. This includes details about work orders, equipment history, spare parts usage, and any other relevant information. The more detailed the data, the better insights you can gain during the RCA process.
Document Equipment Failures: Use the CMMS to document equipment failures and issues. Include information such as symptoms, observed problems, and any immediate corrective actions taken. This documentation serves as a starting point for RCA.
Utilize CMMS Reporting Tools: Take advantage of the reporting tools within the CMMS to generate reports and dashboards related to equipment performance, maintenance activities, and failure analysis. These reports can highlight trends and areas that require further investigation.
Analyze Failure Patterns: Use the CMMS data to analyze failure patterns and trends. Identify equipment or systems that experience repeated issues, and look for commonalities in the failure modes. This analysis helps in pinpointing potential root causes.
Review Maintenance History: Review the maintenance history stored in the CMMS to understand past maintenance activities, replacements, and repairs. Look for patterns that may indicate recurring issues or areas requiring improvement.
Collaborate Across Departments: Encourage collaboration between maintenance teams, operators, and other relevant departments. The CMMS can serve as a centralized platform for sharing information and insights, fostering a collaborative approach to RCA.
By implementing CMMS into the RCA process, organizations can benefit from a systematic and data-driven approach to identifying and addressing the root causes of maintenance issues. This not only improves equipment reliability but also contributes to overall operational excellence and continuous improvement.
Conclusion
In summary, CMMS enhances the effectiveness of Root Cause Analysis by providing a centralized platform for storing, managing, and analyzing maintenance-related data. The system contributes to a more informed and data-driven decision-making process, ultimately leading to improved equipment reliability and reduced downtime.
CMMS
Efficient Work Order Management with CMMS
Introduction
The CMMS solution serves as a crucial tool for companies, enabling them to effectively manage their maintenance operations and consolidate all relevant information in a centralized database, benefiting all parties involved.
In the 1980s, the idea of CMMS (Computerized Maintenance Management System). This revolutionary concept brought about significant improvements in the working environment for maintenance personnel by enabling the computerization of work orders, efficient resource planning, and on-demand printing capabilities.
In the present day, CMMS incorporates not just various forms of maintenance (such as corrective, preventive, conditional, and predictive maintenance) but also encompasses supply management, operational assurance, and integration with production systems.
In order to enhance work planning efficiency, facilitate seamless information transfer through integration with accounting systems, and provide a range of other indispensable functionalities, CMMS has become an essential tool for any responsible business.
Industries that heavily rely on equipment and meticulous monitoring of operations, such as manufacturing, food processing, aviation, and transportation, find maintenance software to be exceptionally valuable. This software is applicable to any sector that necessitates the utilization of heavy machinery.
What is a Work Order?
A work order is a document used to detail the details of a request for goods or services received from a customer. In some industries, the work order is created using information obtained from a sales order prepared by the salesperson working with the customer. There are also situations where the sales order and the work order are the same document, with the terms used to identify the current status of the fulfillment of the customer's request.
The exact structure of the work order will vary depending on the type of goods or services required. For example, the landlord can open a work order in response to a tenant's request to have a room in their apartment painted. The owner will prepare the order in a way that documents the task at hand, the materials needed to complete the job, the time needed to handle the repainting, and the expenses involved in successfully completing the task. In this application, the work order essentially functions not only as a record of the client's request, but also as the escalation list of steps needed to complete the job, and a record of how much it will cost the owner to comply.
The work order in a manufacturing plant is often prepared from data obtained from a customer order drafted by the sales department. Here, the order will include details of the product ordered, including size, number of units, color, and any other applicable information. The ticket will often include details of the delivery date agreed between the sales department and the customer. If the customer has expressed a preference regarding the method of shipping the items ordered, this information may also be included on the work order.
Regardless of the context, the purpose of the work order is to ensure that all parties involved in the fulfillment process know exactly what the customer has ordered, what it will take to fulfill that order, and when the order needs to be fulfilled. From this perspective, the order can be viewed as a necessary document that increases the potential for products to be prepared to customer specifications and delivered to the customer in a timely manner. For this reason, small and large businesses are very likely to use this type of document in one form or another.
Other phrases that business people could use in place of work orders are:
Service ticket
Job order
Work ticket
Job ticket
The Purpose of Work Orders
Such a document is only meant to serve the single function of maintaining a record of all work authorizations, service provider information, charges, and job completion times. A service ticket can be created by both internal and external clients, such as customers and staff.
Depending on whether it is an internal or external request for work, the paper is then sent to the appropriate team. Vouchers are frequently created by businesses using computer software and circulate through numerous physical or digital desks.
Find a quick list of the following work objectives here:
Describe the problem, the fix, and the installation or delivery of the products
The provision of materials and tools required for the task or maintenance work
Provide thorough instructions on the work, job, or maintenance to the technicians
Recording formally the resources, labor, and materials used to complete the work
Track all repair and maintenance jobs that have been performed on each authorization
Contains monetary data like cost, taxes, levies, cess, etc.
What Is Work Order Management?
The management of work orders encompasses the creation, tracking, and administration of these documents within a company. A work order serves as a written or digital record outlining the tasks, instructions, and prerequisites necessary to carry out a specific job or project. The process of work order management encompasses a range of activities, such as:
Initiation of tasks or projects for employees, contractors, or service providers is facilitated through the creation of work orders. These orders encompass crucial information such as the nature of the work, location, deadline, necessary materials, and any specific instructions.
When a work order is generated, it is then allocated to the suitable individuals or team who are accountable for carrying out the specified tasks. Assignments are determined by considering factors such as expertise, availability, and workload.
The entire lifespan of a job or project involves the meticulous tracking of work orders. This entails closely monitoring the status of each individual work order, keeping tabs on the progress made, and meticulously documenting any alterations, setbacks, or complications that may occur during the execution of the work.
Efficiently managing work orders requires effective scheduling and resource allocation to ensure timely and cost-effective completion. This often entails coordinating with various teams, departments, and external vendors to streamline operations and meet project deadlines while staying within budget.
In work order management, it is crucial to have effective communication to keep all parties involved updated on the progress of work orders, any modifications to requirements, and any potential problems that may arise. This can be achieved through various communication methods, including emails, phone calls, and collaboration platforms.
The process of work order management requires thorough documentation of pertinent details for each individual work order. This includes capturing information such as job specifics, costs associated with labor and materials, time allocation, and the status of completion. Precise and comprehensive documentation plays a crucial role in monitoring expenses, evaluating performance, and ensuring adherence to regulatory requirements.
The work order is considered finished and officially closed in the system after all necessary tasks have been completed. This closure triggers the generation of any final documentation or reports. Additionally, work order management includes the crucial step of evaluating the overall performance of the work order process. This evaluation aims to identify specific areas that can be improved upon and implement changes accordingly. The ultimate goal is to enhance both the efficiency and effectiveness of the work order system.
Work Order Management Terms
Work Approver – The assignment and authorization of maintenance requests for equipment management are handled by an administrative or a member of that team. The approver function may occasionally be performed by the warehouse manager and the front desk support for customer interactions.
Work Requester – The person or group that makes the request to execute a certain task is known as the requester. In the services and goods sector, customers generate task orders through online or in-person purchases. Business-to-business requests for work may originate from commercial clients or an internal team, such as when a manager of customer service operations demands workstation maintenance.
Field Technicians – Field technicians are engineers, millwrights, repair personnel, etc. who are qualified to carry out the task specified in the work order document in maintenance job tickets.
How To Effectively Manage Work Orders With a CMMS?
The management of work orders encompasses the creation, tracking, and administration of these documents within a company. A work order serves as a written or digital record outlining the tasks, instructions, and prerequisites necessary to carry out a specific job or project. The process of work order management encompasses a range of activities, such as:
Initiation of tasks or projects for employees, contractors, or service providers is facilitated through the creation of work orders. These orders encompass crucial information such as the nature of the work, location, deadline, necessary materials, and any specific instructions.
When a work order is generated, it is then allocated to the suitable individuals or team who are accountable for carrying out the specified tasks. Assignments are determined by considering factors such as expertise, availability, and workload.
The entire lifespan of a job or project involves the meticulous tracking of work orders. This entails closely monitoring the status of each individual work order, keeping tabs on the progress made, and meticulously documenting any alterations, setbacks, or complications that may occur during the execution of the work.
Efficiently managing work orders requires effective scheduling and resource allocation to ensure timely and cost-effective completion. This often entails coordinating with various teams, departments, and external vendors to streamline operations and meet project deadlines while staying within budget.
In work order management, it is crucial to have effective communication to keep all parties involved updated on the progress of work orders, any modifications to requirements, and any potential problems that may arise. This can be achieved through various communication methods, including emails, phone calls, and collaboration platforms.
The process of work order management requires thorough documentation of pertinent details for each individual work order. This includes capturing information such as job specifics, costs associated with labor and materials, time allocation, and the status of completion. Precise and comprehensive documentation plays a crucial role in monitoring expenses, evaluating performance, and ensuring adherence to regulatory requirements.
The work order is considered finished and officially closed in the system after all necessary tasks have been completed. This closure triggers the generation of any final documentation or reports. Additionally, work order management includes the crucial step of evaluating the overall performance of the work order process. This evaluation aims to identify specific areas that can be improved upon and implement changes accordingly. The ultimate goal is to enhance both the efficiency and effectiveness of the work order system.
Important Features of a CMMS Work Order Management System
When it comes to a comprehensive CMMS work order management system, it is crucial to incorporate the following key features:
Effortlessly and effectively create work orders by providing specific information such as job description, location, priority level, deadline, and necessary materials or resources.
To enhance efficiency and maintain uniformity, the creation process of work orders can be streamlined through the utilization of customizable templates, which are pre-designed for various types of tasks such as preventive maintenance, corrective maintenance, and inspections.
Work order assignment and scheduling are crucial tools for effectively distributing tasks to maintenance technicians or teams. These tools take into account various factors, including skills, availability, and workload, to allocate work orders efficiently. Additionally, the system should enable seamless scheduling and dispatching of work orders to guarantee timely completion of tasks.
Users can conveniently track the status of their work orders in real time, enabling them to stay updated on progress, receive timely notifications, and address any potential delays or issues that may arise.
The capability of accessing work orders through smartphones or tablets while in the field enhances mobile accessibility. This functionality enables technicians to view, update, and finalize work orders instantly, resulting in improved communication and efficiency.
The integration of inventory management functionalities allows for tracking spare parts, tools, and materials necessary for maintenance tasks. The system should be capable of monitoring inventory levels, tracking stock, and automatically initiating reordering processes to guarantee the availability of essential components when required.
The integration of asset management functionality enables the linking of work orders to specific equipment or assets that are in need of maintenance. This seamless connection allows users to conveniently access asset history, maintenance schedules, and pertinent documentation directly from the work order.
The preventive maintenance scheduling feature offers a range of tools to streamline the process, such as built-in scheduling tools that allow users to set up recurring maintenance schedules, define task frequencies, and automatically generate work orders based on predefined criteria.
The ability to include supporting materials such as documentation, manuals, schematics, and photos with work orders is a valuable feature. This functionality enables technicians to easily access and reference relevant information and instructions, enhancing their ability to efficiently complete tasks.
Maintenance performance reports, key performance indicators (KPIs), and metrics can be generated through the reporting and analytics functionalities. Users have the ability to analyze various data points, including work order completion rates, downtime trends, and maintenance costs, in order to pinpoint opportunities for enhancement and optimization.
To ensure seamless data sharing and maintain consistency throughout the organization, it is essential to integrate with external systems, including enterprise resource planning (ERP) systems, asset management software, and accounting software.
To safeguard sensitive information and maintain strict control over user access, role-based access control and security measures are implemented, allowing only authorized users to view, create, or modify work orders.
Benefits of a CMMS Work Order Management System
Organizations across different industries can reap numerous benefits from implementing a CMMS (Computerized Maintenance Management System) work order management system.
By utilizing CMMS work order management systems, the consolidation of all work orders into a single, user-friendly platform is achieved, leading to a reduction in paperwork and the elimination of manual procedures. This centralized method enhances organization and guarantees the streamlined tracking and efficient management of all work orders.
CMMS systems enhance maintenance efficiency by optimizing the creation, assignment, and tracking of work orders. This streamlining process enables technicians to swiftly access work orders, prioritize tasks, and communicate updates in real-time. As a result, response times are accelerated, and downtime is minimized.
CMMS work order management systems offer organizations the ability to optimize resource allocation through enhanced visibility into work order schedules, technician availability, and resource demands. This guarantees that tasks are assigned to the appropriate resources at the precise moment they are needed.
The implementation of CMMS systems results in enhanced productivity for maintenance teams by automating workflows and optimizing processes. This allows technicians to allocate less time towards administrative duties and dedicate more time towards carrying out maintenance work, resulting in increased output and elevated service quality.
The implementation of preventive maintenance is made easier with the assistance of CMMS work order management systems, which enable the creation and organization of preventive maintenance tasks. By proactively addressing potential problems and staying ahead of equipment failures, organizations can effectively reduce unplanned downtime and prolong the lifespan of their assets.
Long-term financial benefits can be achieved through the implementation of CMMS work order management systems, which streamline maintenance processes, minimize downtime, and prevent expensive equipment breakdowns. Additionally, these systems provide enhanced visibility into maintenance costs, empowering organizations to pinpoint opportunities for cost reduction and operational efficiency.
CMMS systems assist organizations in guaranteeing compliance with regulatory obligations and industry benchmarks by providing comprehensive records of maintenance operations and the history of work orders. These records serve as evidence of compliance during audits and inspections.
The implementation of CMMS work order management systems enhances communication and collaboration within maintenance teams, supervisors, and other stakeholders. Through real-time updates, notifications, and messaging capabilities, seamless communication is achieved, resulting in enhanced coordination and teamwork.
The utilization of CMMS systems enables organizations to gather essential data and gain valuable insights regarding maintenance performance, equipment reliability, and asset health. This data can be utilized to detect patterns, assess performance metrics, and make informed decisions based on data to enhance maintenance strategies and optimize overall operations.
The ability to scale and adapt is a key feature of CMMS work order management systems. These systems can easily adjust to the evolving needs of organizations, whether they are overseeing a small facility or a large enterprise. With the capacity to accommodate growth and expansion, CMMS systems remain flexible and capable of supporting changing maintenance demands.
Conclusion
By effectively utilizing the features and functionalities of your CMMS system and following the steps outlined in this blog, you can optimize work order management, enhance maintenance efficiency, and extend the lifespan of your assets.
CMMS
Best CMMS Software & Platforms in 2024
A computerized maintenance management system (CMMS) is essential for the coordination of all activities related to the availability, productivity, and maintainability of complex systems. Modern computer resources have made it possible to considerably improve the effectiveness and efficiency in the field of maintenance through the use of CMMS. The software has evolved from relatively simple mainframe scheduling of maintenance activities to multi-user systems that cover a multitude of maintenance functions. The ability of CMMS to process large amounts of data in a targeted and rapid manner has opened up new possibilities for maintenance, facilitating a more deliberate and thoughtful approach to asset management.
In this article, you can learn about the best CMMS software solutions available on the market today. With this information, you can compare one solution to another and weigh its pros and cons. This can help narrow down your options for CMMS software solutions and ultimately choose the one that is best for your business.
What Is A CMMS?
The acronym CMMS stands for Computerized Maintenance Management System. This software package was designed to manage maintenance globally, on a strategic, financial, and operational level. It is today the essential software of the industrial sector. Much more than simple computer programming, it is an assistant for maintenance teams, the cornerstone of industrial efficiency.
Because you can use it to achieve different goals, there are different ways to describe computerized maintenance management software. On the one hand, it is sophisticated software that captures and uses thousands of data points to provide an overview of how a facility is an operating or detailed information about individual pieces of equipment. In terms of functionality, CMMS software offers businesses the ability to monitor inventory levels, manage work orders, set up and schedule preventive maintenance programs, and quickly generate accurate reports. But on another level, it's just the solution maintenance managers need. Automating processes and streamlining workflows makes your life less stressful by making your workday more predictable.
How Does A CMMS Work?
The easiest way to understand how it works is to first look at two old ways of managing maintenance, paper, and spreadsheets.
With paper, you always run the risk of losing or corrupting data. Every time you doodle a new work order, chances are you'll include mistakes. And even if you copy everything perfectly, chances are someone will lose that piece of paper, your only copy of that essential data. With spreadsheets, it's the opposite problem. The risks of copying and pasting bad data are still there, but now you often have too many copies of the same data. Why is this a problem? Because as soon as someone updates one copy's information, all other disconnected copies are out of sync. In the end, each member of the team works from their own version of the truth. Everyone is out of it, but no one realizes it.
What Is The Role Of A CMMS?
Essential in the industrial sector, the CMMS has many uses. In particular, it allows operational staff and the management team to:
Knowing and identifying and managing the equipment to be maintained: inventory, location, management of relative information by type of equipment.
Manage maintenance: preventive, curative, corrective, and improvement.
Manage intervention requests.
Manage spare parts stocks: by keeping the store up to date, better-controlling restocking, and paying attention to stock valuation.
Manage purchases of supplies and services (equipment rental): purchase requests, orders, and supplier invoicing.
Coordinate staff and schedules: activities, jobs, load plan, forecasts, etc.
Manage costs and budget: preparation of budgets, periodic monitoring, reports of variances between forecasts and actual costs, etc.
Monitor the performance of the activity thanks to the key performance indicators represented in the form of dashboards specifying the requests, the statistics, the number of alerts, the MTTR (Mean Time To Repair), MTBF (Mean Time Between Failures), Pareto's law, etc.
Best CMMS Software & Platforms in 2024
Unplanned downtime can cost companies billions in lost revenue. Often, such outages can be traced back to equipment failure, which can be easily avoided by choosing the right maintenance management software. It allows you to monitor device activity to avoid costly downtime.
In this paragraph, you can learn about the best CMMS software solutions available on the market today. With this information, you can compare one solution to another and weigh its pros and cons. This can help narrow down your options for CMMS software solutions and ultimately choose the one that is best for your business.
WorkTrek
That's us!
The most important thing is to find the solution that best suits your needs, which means that the best CMMS software is often the one that best meets your expectations. And we try to fulfill those expectations!
Benefit from the advantages of the WorkTrek CMMS system:
Efficiently organized maintenance processes.
Better understanding to focus on results.
Opportunities to manage costs.
Better availability of your assets.
Our services are focused on accommodating your business needs, increasing user adoption, and providing you with ongoing support to resolve maintenance issues and challenges faster.
The cloud solution aims to reduce or entirely eliminate paper-based processes by offering a complete set of planning, recording, reporting, inventory, and budgeting functionalities. Users can efficiently search for work orders, track parts, and get notifications about scheduled maintenance or low inventory.
WorkTrek CMMS provides businesses with fully customizable reporting functionality that allows for the creation of work orders, project management, parts, equipment, and location reports.
WorkTrek’s desktop and mobile tools help organize business processes so everyone knows what to do and when. This reduces costs and increases system availability.
What users like about Worktrek:
“Better visibility - As an elevator maintenance company, we had many challenges working in the field, such as a large number of work orders and their organization. The need for a CMMS system became apparent. WorkTrek application helped us greatly in better visibility, control, and organization of work. With the WorkTrek mobile application, our technicians have a clearer division of work tasks, which improves their efficiency. We are particularly pleased with the support and promptness of the WorkTrek team.”
Damir Fabijanković,
Service Manager, METUS
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Click Maint CMMS
Click Maint CMMS focuses on ease of use and user experience. Click Maint has an intuitive interface, ensuring users can navigate and learn the software easily, which supports user adoption and reduces training time. Click Maint comes with all the essential features expected in a CMMS: work order management, preventive maintenance, scheduled inspections, asset and inventory management, cost and resource tracking, and easy-to-use reports and KPIs. Companies looking to improve processes for managing work orders, maintenance requests, and preventive maintenance should check out Click Maint CMMS software.
Pricing:
Click Maint is an affordable CMMS at only $35 USD/month per user. Pricing is straightforward and includes request and work order management, preventive maintenance, asset and inventory management, reports, and KPIs. This price includes access to the mobile app and access to its API for integrations.
Pros: Click Maint offers great value at its price point. Businesses looking for a simple CMMS that is affordable and easy to implement should consider Click Maint. The software is affordable, quick to implement, easy to use and adopt. This translates into fast ROI and speed to value.
Cons: More advanced features like multi-language, predictive maintenance, tool crib, and 21 CFR Compliance are currently not available. Businesses that have more complex maintenance operations and require enterprise functionality, should consider other options. Click Maint is geared toward SMB and mid-market organizations.
Fabrico
Fabrico CMMS is a cloud-based CMMS, enabling the implementation of lean maintenance processes. It integrates end-to-end maintenance strategies that lead to 50% less downtime and 20% less spare parts costs.
With Fabrico, planning, prioritising and assigning maintenance tasks is seamless. Their CMMS app allows for fluent team collaboration and communication.
Fabrico digitises all maintenance processes in manufacturing plants, leading to a significant reduction in emergency repairs. It uses the right CMMS tool for preventive and reactive asset maintenance. This helps with full regulatory compliance through an efficient ticketing system.
Fabrico's CMMS offers a one-day integration into your plant. Meanwhile, its user interface is intuitive and user-friendly.
Industries served: Automotive, chemical, food manufacturing, electronics, machinery, mining and more.
Key Features
Analytics and Reporting
QR code scanner
1-day configuration
Ability to import 100% of all lists
Preventative maintenance
Emergency repairs
Allocation of notifications
Work cards
Task planning calendar
Spare parts storage
Web, Android and iOS applications
ISO Compliance
Self-explanatory nature, reducing the need for training
Pricing
Fabrico calculates its pricing on a per-plant and not a per-user basis. So, the cost plan is affordable. Below are the different pricing options available.
Free: €0 (for those looking to try out all of the product’s features, with an unlimited duration).
Light: €420 per month (the ideal solution for small plants).
Full: €800 per month (suitable for medium and large plants).
Enterprise: Custom pricing (best for bespoke enterprise needs).
To ensure a smooth integration into your maintenance operations, we've prepared a guide outlining comprehensive CMMS implementation steps. Тhis CMMS software also enables easy reporting on maintenance operation KPIs with automated preventive maintenance scheduling.
NEXGEN
NEXGEN Asset Management is a sophisticated Computer Maintenance Management System that integrates asset planning features into one comprehensive program. With over two decades of experience in asset management and software implementation, NEXGEN Asset Management is a web-based system that was curated specifically to support an all-inclusive asset management program.
NEXGEN Asset Management provides engineering, management, and technology consulting services and produces software solutions. They bring over 25 years of consulting experience in engineering, operations, maintenance, management, and technology. The unique combination of their expertise gives them a comprehensive perspective of asset management solutions. The synergies between their software developers, management consultants, and engineers have resulted in the development of NEXGEN Asset Management, the industry-leading asset management software.
UpKeep
UpKeep is a solution that helps maintenance, reliability, and operations teams manage the day-to-day tasks associated with asset management. It provides maintenance teams with a central location to organize inventory, work orders, and budgets and allows technicians to self-help conveniently and instantly, no matter where they are.
Reliability teams use UpKeep for asset performance management to measure and optimize the long-term efficiency of assets throughout their lifecycle. Operations teams use real-time performance monitoring to gain insight into key business metrics by remotely monitoring conditions using sensors and UpKeep's edge platform.
Limble CMMS
Users faced a major problem when dealing with a mobile-first CMMS, including repeated interruptions to phone work requests. This plays a major role in slowing down the workflow of the management and maintenance team.
However, you can solve this problem if you opt for a mobile-first CMMS called Limble CMMS. Here the developers took special care to eliminate the problem of frequent interruptions caused by phone work requests while the maintenance team was working. This helps keep the workflow smooth and fast.
MaintainX
MaintainX is a mobile-first, cloud-based, and IoT-enabled workflow management platform for frontline and industrial workers. Their easy-to-use software allows users to efficiently manage work orders by automating repetitive tasks. Additionally, it encourages employees to be proactive through real-time messaging and clearing backlogs or bottlenecks. MaintainX also helps reduce costs by providing timely reporting with transparent insights into when improvements are needed at the right time.
MaintainX Key Features: Auto-sends notifications when inventory runs low; Enables QR and barcode scanning to save time on inventories; Generates work orders automatically if preventive maintenance fails; Keeps an audit trail of progress to reduce risks and foster accountability; Keeps teams in the loop through the mobile app.
Wrike
Wrike is project management software that helps freelancers and businesses of all sizes get a holistic view of their teams' workloads and collaborate in real-time. With Wrike, teams can improve their work and have a single source of information and communication. The solution can be used not only by project managers, but also by teams in marketing, creative, business operations, professional services, and more. A key feature of Wrike is its trademark Work Intelligence, which combines artificial intelligence and machine learning technologies to positively impact your business. On the other hand, you can check the progress of your projects using interactive Gantt charts and Kanban boards. Wrike integrates with over 400 apps, including Slack, Salesforce, Google Drive, and Microsoft Sharepoint.
What's unique about Wrike? Vision check - This feature allows users to send feedback, files, and approvals in one place to avoid email threads. It also allows users to collaborate in context by identifying which part of the output needs modification. Using this tool, users can easily find brand assets to ensure consistency in their campaigns and messaging. Customized application form - Wrike helps users create request forms with custom fields and different types of questions to choose from. Users can intelligently automate forms by adding conditional steps that change based on the answers given.
Fiix
Fiix creates smart, easy-to-use maintenance management software that helps companies organize their maintenance services and turn data into actionable insights. Its innovative cloud-based CMMS system is multi-tenant, engages maintenance personnel with an unparalleled mobile experience, and seamlessly interfaces with enterprise software to connect your entire business, revolutionizing the way thousands of companies plan, organize and track maintenance.
Fiix is a cloud-based asset and maintenance management solution that allows users to manage preventive and scheduled maintenance, work orders, equipment and resources, parts inventory, purchasing, reporting, and more.
With Fiix, users can create, manage and assign an unlimited number of work orders and receive notifications each time an assignment is completed. Technicians can attach images, videos, and files to work orders, including work instructions, and track hours worked, parts used, and resources used. Multiple resources can be added to work orders and tasks can be copied to create inspection cycles. Work orders for scheduled and preventive maintenance can be automatically generated based on various trigger criteria, including time, date, meter readings, alarms or other events.
Fiix includes tools for tracking asset and spare parts turnover between different work orders, sites, facilities, and external repair shops. Permissions can be managed so that staff can submit requests before moving resources between sites and control who is responsible for approvals and denials for individual site requests. MRO (maintenance, repair, and overhaul) inventory and purchasing can also be managed with Fiix, with an integrated MRO marketplace and the ability to electronically create and send purchase orders and quote requests.
eMaint CMMS
eMaint Computerized Maintenance Management System (CMMS) software helps increase asset reliability and extend equipment life with excellent customer support. You can minimize labor costs by standardizing workflows and optimizing operations with eMaint. Use the system to manage work orders, automate PM schedules, and ensure spare parts availability. Cloud-based technology enables teams to access crucial data from anywhere, whether they are on-site, in the field, or working remotely.
eMaint is part of the Fluke family and is an award-winning CMMS solution designed, both in its software and in its delivery model, with the idea of partnership. Its adaptive interface enables users to connect data for actionable insights, connect teams for streamlined operations, and connect systems for extended ROI.
Hippo CMMS
Hippo CMMS is a maintenance management software tool for businesses of all sizes. It is fast and easy to implement SaaS solutions. Hippo CMMS offers a custom interface that can be designed according to users' operational maintenance needs.
Hippo CMMS designed its CMMS software with the goal of "simplifying complexity". It offers the features businesses need to streamline their operations while being intuitively designed. This CMMS can be used by everyone in an organization, whether it's a VP, CIO, or non-technical employee. The system allows all employees (regardless of hierarchical rank) to process work orders, process maintenance requests, manage preventive maintenance and spare parts,
Hippo CMMS is equipped with all the modules and functionalities needed to streamline maintenance operations: maintenance request portal, on-demand work order management, preventive maintenance, inventory management, fleet maintenance, and maintenance order management. mobile work, reporting, and extraction tools. Each subscription offers an unlimited number of users.
Hippo CMMS's training and support staff help track customers' onboarding from start to finish and support them throughout their subscriptions. Hippo offers a range of services to ensure the implementation goes smoothly: site audits, data migration, software customization, and onsite and web training.
Which CMMS Should You Choose?
Selecting CMMS software requires careful consideration of several key factors. When evaluating CMMS options, consider the software's features and functionality, ease of use, ability to integrate with other systems, customization options, and mobile access.
Also evaluate the level of software training required, data security measures, and customer support options.
The most important thing is to find the solution that best suits your needs, which means that the best CMMS software is often the one that best meets your expectations. And WorkTrek tries to fulfill those expectations!
CMMS
The Role of CMMS in Remote Work
Introduction
CMMS in Remote work has become increasingly popular and widespread, particularly with advancements in technology and changes in workplace dynamics. The COVID-19 pandemic further accelerated the adoption of remote work as organizations shifted to remote operations to ensure employee safety and business continuity. As a result, remote work is now a common and viable option for many employees and organizations worldwide.
What is CMMS?
CMMS stands for Computerized Maintenance Management System. It's a software solution used by organizations to streamline maintenance operations, manage assets, schedule and track maintenance tasks, and optimize resources. CMMS software helps businesses keep track of equipment maintenance schedules, work orders, spare parts inventory, and maintenance histories. CMMS is used in industries such as manufacturing, healthcare, facilities management, transportation, and utilities to improve maintenance efficiency, reduce downtime, and extend the lifespan of assets.
What is Remote Work?
Remote work, also known as telecommuting or telework, refers to a work arrangement in which employees perform their job duties from a location outside of the traditional office environment. Instead of commuting to a physical office, remote workers typically work from home, a co-working space, or any other location with an internet connection.
Key characteristics of remote work include:
Flexibility: Remote work offers flexibility in terms of where and when work is performed. Employees have the freedom to choose their work environment and set their own schedules, within the parameters established by their employer.
Technology-Enabled: Remote work relies heavily on technology, such as computers, internet connectivity, collaboration tools, and communication platforms, to facilitate work-related tasks, meetings, and interactions.
Communication: Effective communication is essential for remote work success. Remote workers rely on email, instant messaging, video conferencing, and other digital communication tools to stay connected with colleagues, supervisors, and clients.
Productivity: Remote work can lead to increased productivity for some individuals, as it eliminates commuting time, reduces distractions, and allows for a more customized work environment. However, it also presents challenges related to work-life balance, isolation, and maintaining focus.
Collaboration: While remote work allows employees to work independently, collaboration remains important for team projects and initiatives. Remote teams use collaborative platforms, project management tools, and virtual meetings to collaborate effectively and achieve shared goals.
Work-Life Balance: Remote work offers the potential for better work-life balance by allowing employees to avoid long commutes, spend more time with family, and pursue personal interests. However, it can also blur the boundaries between work and personal life, leading to challenges in disconnecting from work.
Remote Management: Managers play a crucial role in supporting and managing remote teams. Effective remote management involves setting clear expectations, providing support and resources, fostering communication and collaboration, and measuring performance based on outcomes rather than hours worked.
You may also like: Boosting productivity with CMMS
The Role of CMMS in Remote Working
CMMS platforms play a key role in supporting remote working by providing tools and functionality that enable maintenance teams to effectively manage assets, track maintenance activities, and collaborate remotely. Here's how CMMS contributes to remote work:
Remote Access: CMMS software can be accessed from anywhere with an internet connection, allowing maintenance technicians, supervisors, and managers to work remotely. This allows teams to view asset information, access work orders and update maintenance records from home, a coworking space or other remote locations.
Cloud-Based Solutions: Many CMMS platforms offer cloud-based solutions that allow users to access the system through a web browser or mobile app. Cloud-based CMMS software ensures that maintenance data is stored securely and accessible from anywhere, making remote working and collaboration easier.
Mobile Capabilities: CMMS mobile apps allow maintenance technicians to perform tasks such as viewing work orders, updating task status and recording maintenance activities directly from their smartphone or tablet. Mobile capabilities enable remote workers to stay productive on the go without having to access a desktop computer.
Remote Monitoring and Alerting: CMMS systems can integrate with sensors, IoT devices, and other monitoring technologies to provide real-time data on equipment performance and health. Remote monitoring capabilities enable maintenance teams to identify issues, receive alerts and take proactive action from remote locations, minimizing downtime and optimizing asset reliability.
Collaboration Tools: CMMS platforms often include built-in collaboration tools such as messaging, commenting, and document sharing, allowing remote teams to communicate effectively and collaborate on maintenance projects. These tools facilitate teamwork, knowledge sharing, and decision-making even when team members are geographically dispersed.
Automated Workflows: CMMS software automates maintenance workflows and processes, streamlining tasks such as work order creation, assignment, and approval. Automated workflows ensure maintenance activities run smoothly even among remote team members, reducing manual intervention and increasing efficiency.
Reporting and Analysis: CMMS systems provide reporting and analysis tools to help maintenance teams analyze performance metrics, track key performance indicators (KPIs), and identify trends. With remote access to reports and analytical data, managers and supervisors can monitor maintenance operations, make data-driven decisions and optimize maintenance strategies from anywhere.
You may also like: CMMS vs Traditional Maintenance
Remote Collaborative Maintenance
How to collaborate remotely with physical assets? What does it mean to fix a system together when everyone is not in the same place? What does remote maintenance actually look like?
Remote collaboration is particularly useful in manufacturing because equipment is often located in different parts of the factory or even in different parts of the world. In these situations, it may not always be possible or practical for maintenance professionals to travel to the equipment site to perform maintenance.
Maintenance teams can use a range of tools and technologies to facilitate remote collaboration. For example, video conferencing software allows maintenance professionals to communicate and share information in real time regardless of their physical location. This is particularly useful when solving problems or seeking advice from colleagues with expertise. In addition, managers can facilitate remote collaboration through remote monitoring and diagnostic tools, allowing maintenance professionals to remotely assess equipment health and identify potential issues.
You may also like: Common CMMS mistakes to avoid
Greater Mobility Among Technicians
For field technicians, CMMS mobile apps are an important tool to increase their efficiency and effectiveness. Using mobile devices, technicians can access work orders, document repairs, and update asset information in real time. Long gone are the days of carrying around cumbersome paperwork or relying on sporadic updates.
Consider a scenario where a technician is called to a remote location to perform an emergency repair. Equipped with the CMMS mobile app, they can instantly view equipment details, view historical maintenance records, and even consult remote experts through video calls to solve complex problems. Not only does this increase technician confidence, but it also ensures that the right decisions are made regardless of physical location.
Advantages of Mobile CMMS for Remote Working
Mobile CMMS (Computerized Maintenance Management System) offers several advantages for remote working environments:
Flexibility: A mobile CMMS provides flexibility in performing work by allowing maintenance technicians to access work orders, update task status, and record maintenance activities from anywhere. Technicians can work from home, in the field, or while traveling without being tied to a physical office.
Real-Time Access: A mobile CMMS provides real-time access to maintenance data and information, allowing technicians to view asset details, review maintenance plans and instantly access history from their smartphone or tablet. This ensures technicians have the information they need to complete their tasks efficiently, even when working remotely.
Improved Communications: Mobile CMMS facilitates communication between remote technicians, supervisors, and administrators through integrated messaging and collaboration tools. Technicians can communicate with colleagues in real time, request help and share the latest information, improving teamwork and coordination.
Increase Productivity: A mobile CMMS enables technicians to complete tasks, update records, and resolve maintenance issues remotely, maintaining productivity on the go. By eliminating the need to return to a central office to access information or perform administrative tasks, a mobile CMMS can help technicians make better use of their time and resources.
Faster Response Times: A mobile CMMS enables technicians to quickly respond to maintenance requests and emergencies, regardless of their location. Technicians can receive work orders, prioritize tasks and initiate repairs immediately via mobile devices, reducing downtime and minimizing service interruptions.
Improved Data Accuracy: A mobile CMMS allows technicians to capture and update maintenance data directly in the system while performing tasks in the field. This reduces the risk of data entry errors, ensures data accuracy and increases the reliability of maintained records.
Offline Functionality: Some CMMS mobile apps offer offline functionality, allowing technicians to continue working in areas with poor or no network connectivity. Technicians can access work orders, view asset information and log maintenance activities offline, with data automatically synchronized once connectivity is restored.
Cost Savings: Mobile CMMS helps companies save costs associated with paper-based processes, manual data entry, and travel expenses. A mobile CMMS helps save costs and increase operational efficiency by enabling remote working and increasing efficiency.
Mobile CMMS offers numerous benefits to remote work environments, including flexibility, real-time data access, improved communications, increased productivity, faster response times, improved data accuracy, offline capabilities, and cost savings. By leveraging the benefits of a mobile CMMS, companies can support remote technicians, streamline maintenance operations, and ensure business continuity even in remote or distributed work environments.
You may also like: Why your business needs a CMMS
What About CMMS Remote Training?
Remote CMMS training involves providing training and instruction on how to use CMMS software through online or virtual platforms. Remote training typically involves virtual sessions in which a trainer walks participants through CMMS software functionality and demonstrates how to enter and retrieve data, create reports, and optimize maintenance processes.
Training also covers preventive maintenance planning, work order management, inventory tracking and other functions necessary for efficient asset or equipment management. Remote CMMS training allows participants to access learning resources from different locations, thereby increasing flexibility and accessibility for different audiences. This approach allows companies to effectively train employees at their own pace without having to be physically present, making it a convenient and cost-effective solution. Let’s look at the pros and cons of remote CMMS training.
Advantages
Value for money:
Remote training eliminates travel and accommodation costs, making it a more cost-effective option.
Participants can attend training at their workplace or at home, reducing overall costs.
Participants can receive training at their own pace and time.
Flexibility:
Remote training provides scheduling flexibility and allows participants to choose a time that is convenient for them.Training sessions can be recorded for future reference, allowing for autonomous learning.
Participants can review specific aspects of the training at their own time and pace.
Remote training can accommodate multiple participants, whereas on-site training limits participants due to available space and facilities.
Global wide:
Remote training can be taken regardless of where participants are located, making it suitable for companies with dispersed workforces.
Remote training is particularly useful for shift workers.
Minimize distractions:
Remote training minimizes disruption to daily operations because participants do not need to leave the workplace to participate.
Disadvantages
Limited practical experience:
Participants may require additional opportunities to gain hands-on experience with the actual equipment and systems they will manage.
Remote training has a general format and is not tailored to a specific process, equipment or industry.
Communication challenges:
Remote training relies on virtual communication tools, which can create challenges in conveying complex concepts or providing instant clarification.
Training does not provide opportunities for further breakdown or repetition of tasks as some users may require.
The ability to obtain immediate or detailed feedback or support is limited.
Possible interference:
Participants may experience distractions in a remote work environment, which may affect their focus, engagement, and motivation during training sessions.
Technical problem:
Technical issues such as internet connectivity or software compatibility may cause interruptions in remote training.
Conclusion
Overall, CMMS system plays a key role in supporting remote working by providing remote access, cloud-based solutions, mobile capabilities, remote monitoring, collaboration tools, automated workflows, and reporting and analytics capabilities. By leveraging these capabilities, maintenance teams can effectively manage assets, track maintenance activities, and collaborate remotely to ensure continuity and efficiency of maintenance operations.
Enterprise Asset Management
CMMS for Energy Management: Best Practices
Energy management today represents one of the most significant application sectors of engineering.
By critically analyzing this area we can understand how important it is for companies and how efficient it can be in terms of results and benefits that organizations can draw.
CMMS is software that can help with overall energy management.
Learn more about how CMMS software can benefit your business.
What is Energy Management?
Energy management is the control, influence, and monitoring of energy consumption in a building or business.
It can help you reduce energy consumption. This is done by mapping energy flows and then implementing energy-saving measures.
Energy consumption is an important cost factor for businesses. After labor and material costs, companies spend the most money on energy. At current energy prices, this percentage will only increase.
Read more about how can CMMS software save you money.
The Benefits Of Energy Management
Energy management can reduce energy consumption. This has several advantages.
Save on energy costs
Energy prices were already soaring, and the war in Ukraine made them even more expensive. As a result, more and more companies are struggling with profitability. Energy management can reduce these enormous costs.
Compliance
The European Union's "Green New Deal" has led to an increasing number of laws and regulations on energy consumption. Consumption standards are becoming more stringent in response to climate change.
As a result, mid-sized businesses face more rules and regulations.
Therefore, implementing energy management systems and related energy management systems can make it easier for companies to comply with regulations.
In addition, solid energy management helps fulfill corporate social responsibility. By reducing energy consumption, you contribute to a healthier planet. Today, many customers want their business to be climate-friendly.
The Functions Of Energy Management And The Digitization Of Maintenance Processes
By energy management we mean all those processes dedicated to the effective management of energy to reduce consumption and increase efficiency of use.
The savings that are obtained by implementing energy management processes are mainly due to the introduction of digital technologies typical of Industry 4.0. IoT (Internet of Things), CMMS software, and industrial automation systems.
The birth of the smart factory based precisely on IoT and real-time analytics. It will determine the increase in energy efficiency and change the relationship with customers and business models.
Therefore equip the smart factory with important tools to start efficiency processes both from an energy point of view.
In this way, habitual waste will be reduced. Inefficient equipment will be replaced with others that will be equipped with innovative technologies capable of preventing future damage.
Learn more about CMMS Facility Management.
The main activities on which the energy management process is based are four:
analyses
monitoring
data collection
management
These four functions ensure efficient results allowing you to obtain significant benefits with great savings in terms of resources.
To carry out these functions which aim to ensure the prevention of damage, the energy management department will have to make use of:
CMMS for Energy Management that ensures precision and facilitates the procedures implemented during the maintenance phases.
the figure of the energy manager. A highly qualified professional who coordinates and manages departments and resources efficiently, cooperating for the success of the company.
The use of CMMS (Computerized Maintenance Management System) therefore helps to optimize the use of machines, anticipating failures, maintenance operations of plants and physical equipment such as vehicles, machinery, infrastructure, communications, and other types of assets.
Next, read about how CMMS software can reduce downtime.
CMMS for Energy Management: Why is it important
These systems adapt to different industrial sectors, where the implementation of the physical infrastructure assumes fundamental importance for all sectors; from manufacturing, and energy to construction and transport, etc.
The fundamental aspect of a mobile CMMS software therefore lies in its database: a data model capable of organizing and supporting the various phases of a system.
To do this, and determine a result, the technologies are activated to start an analysis process divided into various phases where in each of these monitoring will be performed at various levels from which data and information are made available.
With the energy management system, it will therefore be possible to detect failures, losses, or anomalies and to have information on the utilities that have been used during the work phases and the times in which production was not active.
Read also 20 benefits of CMMS for businesses
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The Benefits Of CMMS: A Monitoring Software For Energy Management
The use of CMMS software allows you to reap many advantages when it comes to managing important processes such as those deriving from energy management activities.
Here are some insights:
Documentation and history management – Among the advantages, first of all, is that a CMMS system can contain any type of information regarding maintenance.
Optimization of maintenance processes – Having a large amount of data available, CMMS software will be able not only to support and optimize maintenance processes but also to provide all the data necessary to make a detailed analysis of the processes themselves, monitoring times, costs, and performances.
All this takes place thanks to business intelligence systems that analyze data and provide personalized and detailed reports.
Check out this blog to learn more benefits of a CMMS.
Transition from reactive to proactive – The derived CMMS data allows you to move from a reactive to a proactive approach so you can develop an advanced asset maintenance strategy.
Data derived from daily activities together with IoT tools can provide information from processes and assets giving the possibility to intervene in time and activate preventive measures before failures occur or performance becomes obsolete.
The best CMMS software can automate most of these processes ensuring that work orders are managed. They are assigned to the correct personnel based on the indications provided to the system.
User resources – CMMS software makes various functions available to users, such as organizing shifts, managing work resources, and assigning tasks to specialized personnel in the sector of their application.
Archive and register – CMMS software holds an internal register capable of storing information on materials management, inventory, supplier management, order tracking, report generation, analysis, and verification of all maintenance categories.
Next, read how employees should be trained for CMMS.
Energy and Power Maintenance Management Challenges
The power and energy industry faces maintenance management challenges for power plants and wind turbines.
Generate safe energy at all times
The operation of nuclear, coal, hydro, and steam power plants requires rigorous procedures. They need to stay online and continuously produce efficient, safe energy. This requires careful maintenance management with consideration for public safety, the environment, and the protection of factory workers.
Equipment must be monitored regularly
Maintenance of equipment, especially wind farms, is more challenging than nuclear power. It requires continuous or frequent monitoring of machine conditions and maintenance accordingly. Workers in this industry adopt best practices from other industries such as industrial manufacturing, mining, and natural resources. The aim is to plan the necessary preventive maintenance measures for wind energy professionals at appropriate intervals.
Continuous inspection
Since plants in the power and energy industry must be in operation at all times, continuous inspections of power plants and wind turbine equipment are essential. These checks ensure that parts are lubricated and system connections are made. They also ensure that necessary repairs are found and made before it develops into an emergency.
Security and Regulatory Compliance
Another challenge in power plant maintenance is meeting regulatory compliance standards, including the Occupational Safety and Health Administration (OSHA), Environmental Protection Agency (EPA), and Federal Energy Regulatory Commission (FERC) standards. This is a challenge as technology in this industry evolves rapidly. What is relevant now may not be relevant anymore in six months to a year. Regular checks for new requirements and ongoing further training in the field are crucial.
Learn more about how to develop a plant maintenance plan.
Control Of Energy Expenditure With A CMMS
Energy consumption has long been an indispensable focus of attention at all levels of our society. The impact we have on our planet has become a growing concern and our energy consumption represents a significant part of the ecological impact on our environment. In addition, in our country, we have been able to observe that the cost of energy has been constantly increasing, in recent years, until it has become a hot topic in the media for months, which makes it another strong argument for regulating and optimizing our consumption.
Fuels, gas, and especially electricity are subjects which have often made the headlines and which must be tackled on different fronts. It is also something that concerns us whatever our field of action.
Maintenance as a solution
The value of good maintenance as an energy efficiency tool in the planning of such a strategy should be highlighted. Ultimately, the costs of maintenance, energy, or upkeep as such represent a very high percentage of the life cycle costs of facilities and infrastructure.
This is why it is necessary to have good maintenance mechanisms, automating recurring preventive maintenance and minimizing the need for corrective maintenance. Not only to avoid deterioration and additional replacement costs but also to reduce the energy consumption of our facilities. By ensuring that all elements operate in their optimal state and without overheating, poor cooling, stagnation or any other incident that ends up causing overconsumption and, therefore, cost overruns.
If maintenance is carried out correctly and if we record the necessary data, we will not only reduce energy costs thanks to the proper functioning of our devices. We will also have the information necessary to research possible improvements in our systems and further optimize our installations.
CMMS solutions, tools that integrate all equipment inventory, maintenance flows, personnel, and work orders into a single environment, have already become very popular. However, today, to stop there is to deprive oneself of the possibility of optimizing the energy efficiency of assets.
Consider reading, CMMS for Healthcare Facilities.
Conclusion
Reduced downtime and lost productivity in today's fast-paced energy production environment, CMMS software is critical. CMMS systems often include advanced functionality not only for asset tracking, but also for job scheduling, labor costs, and inventory tracking. It also helps maintenance teams keep detailed records of their equipment and assets.
CMMS
CMMS vs Traditional Maintenance
Introduction
As companies become larger and more complex, managers feel pressure to keep up with trends and demands. So they try to act smarter and smarter. This means companies seek to achieve a high return on investment by improving operations through better time management, cost reduction, labor management and extending equipment life. Companies are gradually realizing that paper-and-pencil management cannot achieve their goals.
Many companies start adopting management solutions after developing computer-based management applications. A CMMS can monitor and track inventory, create work orders with accurate reporting, and most importantly, perform preventive maintenance on needed assets.
A preventive maintenance approach includes regular equipment inspections, an important aspect of a service plan. Companies prefer to use it instead of reactive methods. A reactive approach will only solve problems when they arise. This can lead to unplanned downtime and equipment failure.
History of CMMS and Traditional Maintenance
Traditional maintenance practices have been used for centuries, relying on reactive and corrective maintenance methods where repairs are initiated in response to equipment failures or breakdowns.
Traditional maintenance involves ad-hoc repairs, routine inspections, and manual record-keeping, with limited emphasis on preventive or predictive maintenance strategies.
The emergence of computer technology in the late 20th century led to the development of CMMS, which revolutionized maintenance management by automating tasks, optimizing processes, and providing real-time visibility into maintenance activities.
CMMS originated in the 1960s and 1970s with the advent of early computer systems and mainframe-based maintenance management software.
Over time, CMMS evolved to incorporate advanced features such as preventive maintenance scheduling, asset management, inventory optimization, and data analytics, enabling organizations to adopt more proactive and efficient maintenance practices.
Today, CMMS has become an essential tool for organizations across various industries, helping them streamline maintenance operations, optimize asset performance, and improve overall operational efficiency.
While traditional maintenance practices are still prevalent in some industries, many organizations are transitioning to CMMS and other modern maintenance management systems to achieve greater reliability, efficiency, and competitiveness in their maintenance operations.
What Does CMMS Software Do and How Does it Work?
The CMMS is a software capable of containing all the maintenance information: from the technical database to the asset sheets, through maintenance plans, requests for technical intervention and work orders. It also allows you to manage all the documentation, the history of interventions and work reports, the spare parts in the warehouse, as well as of course the technicians and suppliers.
Thanks to all this information, it is able not only to help you optimize maintenance processes, but also to provide all the data necessary for a detailed analysis of them, monitoring times, costs and performance thanks to business intelligence systems that analyze the data for you, creating personalized and incredibly detailed reports.
The best CMMS software is also able to automate a large part of these processes, for example by automatically creating work orders or assigning them, always automatically, to the right personnel, based on the indications you have given to the system.
Let's say for example that you need to plan preventive maintenance interventions based on the working time of a machine. The CMMS is able to generate a new work order every time this time is reached, inform you if spare parts are available in stock, attach the necessary documents and maintenance checklists to ensure that the interventions are carried out in the correct way and finally assign them to the personnel indicated on the basis of the machinery or its location.
This allows you to drastically reduce the costs and management times of your resources, as well as naturally machine downtime, also reducing manual actions and margins of error.
One of the most important features of modern CMMS systems is the ability to use the mobile app.
Thanks to the mobile app, technicians can take the CMMS for company maintenance with them wherever they go in the field. They will be notified via a simple notification (or an email) when they are assigned a work order, they will be able to consult the documentation, record the intervention times, take advantage of the checklists attached to the work order and add the pieces in just a few taps spare parts used on the final report.
This will allow them not only to cut intervention times, but also to automatically record all data and information relating to the work order within the CMMS system. Once the intervention is completed, they will be able to automatically generate the end of work report, create it directly on their phone and send it to the system (as well as by email to the figures involved).
At this point the CMMS system records the data and sorts them within the platform, where they will be available in real time.
Likewise, the maintenance manager will have a complete view of the progress of maintenance operations, will be able to easily monitor, without any additional action, the work orders carried out and those still to be carried out, as well as analyze the recorded data in real time.
Advantages of CMMS
Implementing a computerized maintenance management system (CMMS) offers numerous benefits to companies across a variety of industries. Key benefits of a CMMS include:
Improve Maintenance Efficiency: CMMS streamlines the maintenance process by automating tasks such as work order creation, scheduling, and tracking. This increases the efficiency of managing maintenance activities, reduces administrative burden and minimizes downtime.
Improved Asset Management: A CMMS provides a centralized platform to track and manage assets, including equipment, machinery, and facilities. Companies can easily access asset information, maintenance history and performance data to optimize asset lifecycle management, improve reliability and extend asset life.
Optimize Preventive Maintenance: With a CMMS, companies can implement preventive maintenance programs based on equipment health, performance data, and manufacturer recommendations. Proactively planning maintenance tasks can help prevent equipment failure, reduce downtime and reduce maintenance costs.
Inventory Optimization: CMMS enables better management of spare parts, consumables, and inventory by tracking inventory levels, managing reorder points, and optimizing procurement processes. This ensures adequate inventory levels, reduces stock-outs and minimizes storage costs.
Data-Driven Decisions: CMMS provides valuable insights into maintenance performance, asset reliability and resource utilization through reporting and analytical tools. Companies can analyze maintenance data, identify trends and make informed decisions to optimize maintenance strategies, increase efficiency and reduce costs.
Improved Compliance and Documentation: A CMMS helps companies maintain compliance with regulatory standards and documentation requirements by storing maintenance records, inspection reports, and compliance documents in a centralized and easily accessible system. This ensures compliance with safety regulations, industry standards and audit requirements.
Reduce Downtime and Costs: By proactively managing maintenance activities, implementing preventive maintenance plans, and optimizing resource allocation, a CMMS helps reduce equipment downtime, minimize emergency repairs, and lower maintenance costs. This will lead to greater productivity, operational efficiency and profitability.
Improved Communication and Collaboration: CMMS facilitates communication and collaboration between maintenance teams, supervisors, and other stakeholders through instant messaging, notifications, and alerts. This improves coordination, teamwork and accountability, leading to better results and performance.
Overall, a CMMS provides businesses with a variety of benefits, including increased maintenance efficiency, improved asset management, preventive maintenance optimization, inventory optimization, data-driven decision-making, compliance and document management, reduced downtime and costs, and improved communication and cooperation. By effectively leveraging CMMS capabilities, companies can achieve greater operational excellence, reliability, and competitiveness in their industry.
What is Traditional Maintenance?
Traditional maintenance is the traditional approach to managing maintenance activities within an organization, often characterized by reactive and corrective maintenance practices. In traditional maintenance, maintenance activities are performed in response to equipment malfunction rather than being planned or scheduled in advance.
Key features of traditional maintenance include:
Reactive Maintenance: Maintenance tasks are initiated in response to equipment failure, often resulting in unplanned downtime and production interruptions.
Fault Repair: Equipment is repaired or replaced only when it breaks down, resulting in higher repair costs, increased downtime and potential safety hazards.
Routine Inspections and Repairs: Maintenance activities such as inspections and repairs are performed on an ad hoc basis or according to a fixed schedule rather than based on equipment condition or performance data.
Limited Predictive Capabilities: The use of data and technology to predict equipment failures or maintenance needs is limited. Maintenance decisions are often based on historical experience or intuition rather than data-driven insights.
High Maintenance Costs: Reactive maintenance practices can result in higher overall maintenance costs due to emergency repairs, extended downtime, and inefficient resource utilization.
Reduced Equipment Reliability: Equipment reliability can suffer due to a lack of proactive maintenance measures to prevent failures and optimize asset performance.
Overall, compared with modern maintenance strategies such as preventive maintenance, predictive maintenance and reliability-oriented maintenance, traditional maintenance methods are often less efficient, more costly and less effective in ensuring equipment reliability and operating efficiency. Many companies are moving from traditional maintenance practices to more proactive, data-driven maintenance strategies to improve asset performance, reduce downtime and optimize maintenance costs.
Disadvantages of Traditional Maintenance
Disadvantages of traditional maintenance include:
Higher Costs: Reactive maintenance practices often result in higher overall maintenance costs due to increased labor costs associated with emergency repairs, expedited shipping of replacement parts, and unplanned downtime.
Increased Downtime: Reactive maintenance can lead to increased equipment downtime because repairs are not initiated until an equipment failure occurs. This can disrupt production plans, reduce productivity and impact profitability.
Safety Risks: Failures caused by equipment failure and reactive maintenance operations can create safety risks for employees and lead to possible injuries, accidents and regulatory compliance issues.
Reduced Equipment Reliability: Reactive maintenance fails to address the underlying issue or root cause of equipment failure, resulting in recurring failures and reduced equipment reliability over time.
Unplanned Production Downtime: Equipment malfunctions and malfunctions can lead to unplanned production downtime, resulting in delayed order fulfillment, customer dissatisfaction and potential loss of business.
Limited Predictive Capabilities: Reactive maintenance practices cannot predict equipment failure or predict maintenance needs based on data-driven insights. This can result in missed opportunities to proactively address maintenance issues before they escalate.
Shortened Equipment Life: A lack of proactive maintenance measures can lead to premature equipment failure and shortened equipment life, requiring more frequent replacements and higher capital expenditures.
Poor Asset Management: Reactive maintenance practices often result in inadequate tracking and recording of maintenance activities, making it difficult to assess asset performance, identify trends and optimize maintenance strategies.
Overall, the shortcomings of traditional maintenance highlight the need for organizations to move to more proactive, data-driven maintenance approaches such as preventive maintenance, predictive maintenance and reliability-centered maintenance to increase equipment reliability, reduce downtime and optimize maintenance costs.
Are there Benefits to Traditional Maintenance?
While traditional maintenance practices have several disadvantages, this approach also has some potential benefits:
Simplicity: Traditional maintenance practices are often easier to implement and manage than more proactive maintenance strategies. They require less upfront investment in technology, training and infrastructure, so they can also be used by smaller organizations with limited resources.
Flexibility: Traditional maintenance practices allow companies to respond quickly to equipment malfunctions and breakdowns and resolve maintenance needs as they arise. This flexibility is useful in situations where equipment failure is rare or unpredictable.
Minimal Planning Required: Traditional maintenance requires less detailed planning and scheduling of maintenance activities in advance. Maintenance tasks can be performed on an ad hoc basis or according to a set schedule without extensive planning or preparation.
Avoid Over-Maintenance: Traditional maintenance practices only repair equipment when it breaks down, which avoids unnecessary maintenance intervention and over-maintenance. This allows companies to avoid spending resources on potentially unnecessary maintenance activities.
Lower Upfront Costs: Reactive maintenance practices typically have lower upfront costs than more proactive maintenance strategies because they do not require investments in predictive maintenance technology, condition monitoring systems, or extensive preventive maintenance programs.
Familiarity: Traditional maintenance practices may be more familiar to maintenance technicians and personnel because they are consistent with traditional maintenance management methods. This familiarity can make it easier for companies to gradually transition to a more proactive maintenance strategy.
While these benefits may apply in some situations, organizations must recognize the limitations of traditional maintenance practices and consider the long-term impact on equipment reliability, downtime, and overall operational efficiency. In many cases, moving to a more proactive and data-driven approach to maintenance ultimately results in greater cost savings, improved asset performance and increased long-term competitiveness.
CMMS vs Traditional Maintenance
Comparing a CMMS softwares to traditional maintenance practices reveals significant differences in approach, benefits and results. Here’s how a CMMS compares to traditional maintenance:
Approach to Maintenance
· CMMS: CMMS emphasizes proactive maintenance strategies such as preventive maintenance and predictive maintenance. The focus is on planning and scheduling maintenance tasks ahead of time based on equipment health, performance data and industry best practices.
· Traditional Maintenance: Traditional maintenance practices are reactive and corrective in nature, with maintenance activities initiated in response to equipment failure. Maintenance is often ad hoc or performed on a set schedule without regard to the health or performance data of the equipment.
Maintenance Efficiency
· CMMS: A CMMS optimizes maintenance processes, automates tasks, and provides real-time visibility into maintenance activities. It improves maintenance efficiency by optimizing resource utilization, reducing downtime and increasing productivity.
· Traditional Maintenance: Traditional maintenance practices can be less efficient, resulting in increased downtime, higher repair costs and greater reliance on manual processes. Maintenance activities are often reactive and may not be optimized for efficiency.
Asset Management
· CMMS: A CMMS provides a centralized platform for tracking and managing assets, including plants, machinery, and equipment. It enables companies to maintain comprehensive asset records, track maintenance history and optimize asset lifecycle management.
· Traditional Maintenance: Traditional maintenance practices may lack robust asset management capabilities, making it difficult to track assets, monitor maintenance activities, and optimize asset performance.
Preventive maintenance
· CMMS: A CMMS helps implement preventive maintenance programs based on equipment health, performance data, and maintenance schedules. It helps prevent equipment failure, extend asset life and reduce downtime.
· Traditional maintenance: Traditional maintenance practices may rely more on reactive maintenance, resulting in more unplanned downtime, higher repair costs, and reduced equipment reliability.
Data-driven decisions
· CMMS: A CMMS provides valuable insights into maintenance performance, asset reliability and resource utilization through reporting and analysis tools. It supports data-driven decision making, allowing companies to optimize maintenance strategies and improve operational efficiency.
· Traditional Maintenance: Traditional maintenance practices may lack the data and analytics capabilities of a CMMS, making it difficult to analyze maintenance performance, identify trends, and make informed decisions.
CMMS vs Traditional Maintenance
Conclusion
While traditional maintenance practices may have been sufficient in the past, a CMMS overall offers numerous advantages in proactive maintenance, efficiency, asset management, preventive maintenance, data-driven decision making, and overall operational excellence. By switching to a CMMS, companies can achieve greater reliability, efficiency and competitiveness in their maintenance operations.
CMMS
Top 6 Free CMMS Software & App
Free CMMS Software
CMMS software streamlines maintenance processes, management, and planning, helping companies ensure consistent performance and increased efficiency. Also, a CMMS tool is used by different sectors of industry in order to support maintenance services in their missions and on a daily basis. Besides, by automating and monitoring maintenance schedules, CMMS software reduces costs and optimizes the process of repairing and replacing key equipment.
We bring you a list of free CMMS systems and see what are the advantages and disadvantages of free CMMS software.
Free IT Maintenance Management Software
Here is a list of free software that has interesting performance in terms of computer maintenance:
1. Excel
All companies have Excel, so this solution is used by many of them, often they use Excel for accounting purposes. Managing maintenance with this software means you don't have to invest in additional software. Then above all, if you already have spreadsheet practice, it's child's play.
What are the benefits of Excel?
Creation of intervention plans.
Data crossing.
Establishment of lists of supplies, equipment, and speakers.
Production of dashboards.
Reporting generation.
Free tutorials on the net to deepen your knowledge and use.
Mastery of Excel by your employees.
Time saving and fluidity.
Nevertheless, Excel is fine to start with, but can be time-consuming, and data traceability is not present.
2. Fiix Lite
Fiix Lite is the free version of the Fiix software. Beside, it offers fewer features than the paid versions, but it allows you to discover the main features of the software. Fiix Lite is often used by companies in the tertiary and service sectors.
What are the benefits of Fiix Lite?
Quick and easy handling.
Professional features.
Mobile app.
Purchase order management.
No credit card is required.
You may already have some sufficient knowledge if you are a small business.
3. MaintenanceCare
MaintenanceCare is an online software that offers maintenance management in a free version. It is the best known in its category, but it is only available in English at the moment. The free version is available for one entity and one user.
What are the benefits of MaintenanceCare?
Mobile app.
Purchase order management.
Asset management.
Preventive maintenance.
Functional coverage.
4. MaintainX
MaintainX is a mobile CMMS (computer-aided maintenance management) task and work procedure digitization software that lets frontline teams know what they need to do and how to get it done.
What are the benefits of MaintainX?
Safety procedures.
Environmental checklists.
Tooling and gauge reporting.
Maintenance procedures.
Audit/inspection workflow.
Checklists training.
Plant managers can become more efficient operators by providing real-time business information in the field.
5. UpKeep
UpKeep's CMMS is a modern maintenance and asset management solution for your team. Whether on your desktop, phone, or even tablet, UpKeep is easily accessible from anywhere, anytime. Create work orders on the go, get notifications when tasks are updated, and get alerts right from your app when resources are depleted. So your business is more efficient than ever.
6. WorkTrek CMMS
WorkTrek is a cloud platform that assists maintenance teams, asset and facility managers, and technicians in streamlining and digitizing their fieldwork, maintenance, and asset management operations. It consolidates your asset data and keeps track of your upkeep activities, paperwork, history of services, spare parts, asset states, and prices. Additionally, it allows you to generate, allocate, and schedule work orders all in one location without having to deal with piles of paperwork. WorkTrek CMMS offers a 30-day free trial!
What Are The Limits Of Free CMMS Software?
If you decide to go with computer-based automated maintenance management, the freeware option can help you get started. However, in the long term, it may be less attractive. Free CMMS software comes with limited features.
Although free CMMS software has the advantage of almost zero acquisition cost, the features you have access to are limited. Indeed, if you want to benefit from software adapted to the growth of your activity, you will have to pay for additional functionalities. Free CMMS software only offers an overview of the features of a complete software to encourage you to subscribe to the paid solution.
Also, the number of users for free CMMS software is limited. As a result, it will be difficult, if not impossible, for all of your technicians to benefit from a free CMMS solution.
Moreover, the freeness of CMMS software is intrinsically linked to the fact that it meets a specific need. For example, to bill your customers, you will opt for precise accounting software. But an additional tool will be required to plan or monitor your interventions in real-time.
What are the main limitations of free CMMS software?
Features are restricted.
The number of users is limited.
The configuration can be complicated if you have no skills in the field.
Lack of customer service or support to help you with any issues.
Advantages Of Paid Professional CMMS Solutions
Paid CMMS software has wider functional coverage.
They are flexible and modular to best adapt to your event.
They provide support and guidance to make the tools easier to use.
They keep your data safe.
They are continuously improved through regular updates.
They are offered in a SaaS (Software as a Service) model: thus the subscription formula allows cost control.
They usually offer a free trial to check if the solution really fits your needs.
Should I Opt For A Professional CMMS Tool?
Switching to a paid professional CMMS tool offers many advantages, starting with much more advanced features than free software. The configuration is much more advanced and allows you to precisely adapt the tool to the needs of your company.
Additionally, opting for a paid solution allows you to benefit from the support and expertise of the publisher. The advisors help you choose the best offer and provide support in the installation of the software and support throughout the duration of use. This represents a considerable saving of time and you will be able to take advantage of it to improve your internal processes and benefit from the feedback from the editor if he has encountered cases similar to yours.
What Are the Benefits of Paid Solution?
Finally, a paid solution allows you to benefit from regular updates to guarantee the security of your data and take advantage of the publisher's latest innovations. In addition, user feedback is regularly taken into account and helps developers to improve the CMMS software continuously and iteratively. The goal of paid CMMS software publishers is to always offer great ease of use and optimal efficiency.
CMMS, A Quickly Profitable Investment
The CMMS is a tool generally considered essential in large industries but often underestimated in small and medium enterprises, because the return on investment is not always clearly perceived. The product is then considered out of reach...
Although, its profitability - even for small companies - is a tangible reality and quite easy to estimate, as we will show you. To calculate the return on investment (ROI) of the CMMS, simply relate the costs and the net gains (gains-costs), according to the following equation:
For example, if the CMMS costs 2500 euros per year to the company, but allows it to save 13250 euros, the ROI is 12.8 for its CMMS. This result is obtained by dividing the net gain (€32,500 – €2,500) by its costs (€2,500).
Identifying the gains may prove to be the only difficulty in this estimation. These must be well identified for the calculation of the ROI of its CMMS platform to be efficient.
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How Much Does A CMMS Cost?
Since most maintenance workers are in the field, CMMS solutions, for Computer Aided Maintenance Management, are usually deployed via the cloud with mobile-friendly interfaces. As a result, CMMS vendors charge businesses on a software-as-a-service (SaaS) pricing model. In a per-user-per-month subscription plan, companies only pay for the number of employees who actually use the software.
These plans often come in multiple tiers based on feature levels and user types, such as technicians, managers, and system administrators. For example, a technician might need work order management functionality, but not business analytics functionality. A manager, on the other hand, may need both functions.
This option is best for small businesses with basic operations and a limited number of users. Some plans also provide a maintenance portal where anyone can submit a work order request.
Here you can see CMMS software prices and book a free demo version on WorkTrek.
How To Choose A CMMS Software?
Several solutions exist and can meet varying expectations. Thus, it will be necessary, first of all, to clearly define the expectations of the maintenance team and the expected depth of field.
It will be necessary to be vigilant about the user experience and the adaptability of the maintenance software to your operating modes.
Additionally, ensure the quality of customer service to deal with possible problems and know that your request will be handled in the shortest possible time. It's when you need it most that you realize the need for a good partnership.
Be sure, then, to choose a scalable solution so as not to end up with a tool that will not evolve over time.
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