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What Is IWMS? Meaning, Benefits, and Features
What Is IWMS? IWMS stands for Integrated Workplace Management System. It’s a software platform used by organizations to manage various aspects of their real estate portfolio, infrastructure, and facilities. IWMS platforms typically offer modules for managing space utilization, lease administration, maintenance, sustainability initiatives, capital projects, and other related functions. These systems provide a centralized database […]
What Is IWMS? IWMS stands for Integrated Workplace Management System. It's a software platform used by organizations to manage various aspects of their real estate portfolio, infrastructure, and facilities. IWMS platforms typically offer modules for managing space utilization, lease administration, maintenance, sustainability initiatives, capital projects, and other related functions.
These systems provide a centralized database and tools for optimizing space allocation, reducing costs, improving operational efficiency, and supporting strategic decision-making related to facilities management and corporate real estate. IWMS solutions are commonly used by large enterprises, government agencies, educational institutions, and other organizations with complex facility management needs.
Modern workplaces require effective management to maintain uptime and productivity. Managing a workplace includes a wide range of tasks such as maintenance, security, asset management, space planning, etc. An efficient workforce depends on the smooth running of back-end processes.
With approximately 82% of businesses experiencing unplanned downtime each year, disruptions affect the entire organization and its employees, with a significant impact on sales and profits.
To address this, an integrated workplace management system (IWMS) brings together a collection of software technologies designed to solve common workplace challenges.
IWMS brings together asset management, building and energy performance, space planning, and other work management functions in one integrated platform.
Here's everything you need to know about IWMS.
Workplace Management: Definition and Key Challenges
Workplace management is a global concept that encompasses the management of services, devices, processes, and technologies that enable employees to work, collaborate, learn, and innovate.
The goal of this people-centered approach to management is to make the work environment work for employees, improving their well-being and user experience.
By establishing and maintaining a good work environment, companies can increase the efficiency and productivity of their employees. Good management practices help achieve these goals while optimizing costs while adapting to changing needs.
Performance and Workplace
IWMS is a concept that goes beyond the traditional functions of facilities management by improving employee performance and collaboration. It's more than a simple support service, it's a strategic tool that can help organizations achieve their goals. It represents significant added value.
Workplace management is a continuous improvement process aimed at achieving the highest level of performance in the corporate workplace. A common denominator among today's most productive organizations is their recognition of the role workplace management plays in employee engagement and productivity.
It can be applied at many different levels, from managing several workplaces to managing a large, internationally distributed real estate portfolio. In any event, it covers all processes to improve workplace performance levels, from strategic planning to the operational use of equipment, including safety, maintenance and catering.
What Is The Integrated Workplace Management System (IWMS)?
The combination of data with business processes in an integrated software solution is an important condition for identifying initiatives to improve profitability and quality, to then implementing them and finally monitoring them continuously. These software solutions are called Integrated Workplace Management Systems (IWMS).
Integrated Workplace Management System (IWMS) is the globally recognized name for software solutions that support facility management and property management processes. This term was launched in 2004 by Gartner. The IWMS solution is described by Gartner as an enterprise-grade software platform integrating five important functional areas from a single technology platform and a single centralized database. These functional areas are:
Real Estate and Lease Management
Facility and Space Management
Maintenance Management
Project Management
Environmental Sustainability
The History of IWMS
Leading technology research firm Gartner first used the term "integrated workplace management system" in 2004 to describe an enterprise-wide program that can manage multiple functional areas. Gartner describes the concept of integration as a "single technology platform, single data repository." The rise of the internet in the late 90s and early 2000s made integration and such platforms more possible - and even more important.
IWMS Functional Areas
The ideal IWMS software integrates multiple functional areas of the workplace that could not have been combined or worked simultaneously, but which now absolutely must work together.
Resource Management
Organizations are moving towards more sustainable practices, and IWMS software supports this trend. Plants are able to measure, analyze and reduce resources and waste consumption – such as water consumption, energy consumption and greenhouse gas emissions. An IWMS enables facility management to leverage capabilities to improve sustainable practices, capture performance metrics and plan for better energy management.
Real Estate Portfolio Management
Corporate real estate professionals can use IWMS software to track items such as leases, contracts, appointments, and disclosures. As the real estate landscape continues to change in the post-pandemic world, it's critical that you have access to data about how all your properties are being used. It's much harder to get a complete picture of your property when you're tracking this information across multiple spreadsheets. An IWMS can help you consolidate, visualize and report on everything so you can make the right long-term planning and investment decisions.
Facility Management
An IWMS helps you optimize asset and maintenance processes and activities. These include:
Maintenance Schedule:
Proactively schedule and automatically assign preventative maintenance to your equipment. With all equipment tracked in one system, you can easily view part information and work history for each asset, saving technicians time searching for data or manually entering information into multiple systems.
Work Orders:
Easily submit work orders to fix faulty equipment and track maintenance or repair work on one platform.
Asset Health Assessment:
Manage asset assessment data to better understand a building's physical condition—including age, structure, and condition of individual rooms and equipment.
Having data for all assets in one place makes it easier to spot short-term and long-term trends. With cloud-based IWMS software for mobile devices, your technicians can access equipment information directly from the palm of their hands.
Capital Project Management
Capital project management typically involves the design and implementation of building extensions or renovations, asset exchanges, and blueprints, all coordinated on the IWMS to provide design, capital management, cost, procurement, scheduling, bidding, critical path analysis, and documentation support.
Sustainability and Energy Management
More and more companies are looking to reduce their carbon footprint, enhance their sustainability efforts and monitor energy consumption.
However, this is becoming increasingly challenging. The Verdantix research also found that as organizations push for mixed work schedules, building occupancy rates will be more volatile. This in turn increases the pressure on facility teams to optimize their heating and cooling equipment to accommodate these fluctuating and low utilization conditions.
Effective IWMS software helps companies analyze their consumption patterns and spot spikes and anomalies in data more easily. This means you can better optimize, predict and reduce energy consumption. Read also, a guide to plant operations management.
How To Get The Most Out Of IWMS Software?
The potential advantages of IWMS software are enormous. However, before making a decision and committing to a system, it is strongly recommended that you detail the benefits you expect from it in order to create an effective specification.
To help you, here are the top 5 key benefits typically expected from IWMS software.
True Knowledge
Many firms know this: a lack of visibility into real estate portfolios in a broader sense leads to significant risks in terms of cost, compliance, and continuity. If you find yourself in this situation, an IWMS solution will help you a lot in planning maintenance, supplier management, understanding the value and characteristics of your assets, and more.
Such a tool allows you to gain an overview by creating a standardized database for all space, equipment, and property management processes: you know exactly which areas you occupy, and you can track subcontractors' work in detail.
Guaranteed Compliance
Ensuring compliance with laws and regulations is a growing headache for facility managers. Whether it's about safety, maintenance, or the environment, standards are becoming more numerous and more stringent, and it's hard to keep up with their evolution.
Therefore, organized and easily accessible documentation is critical to ensuring compliance with their facility and being able to demonstrate this in the event of an audit or incident.
IWMS software typically provides features that ensure compliance with standards and provide all employees who need them with the necessary files to take into account when performing their tasks.
Better Space Management
In many companies, workplaces are often underutilized, sometimes without managers even realizing it. The use of IWMS allows on the one hand a reliable diagnosis of the occupancy of offices, workplaces, and conference rooms, and on the other hand, implements another measure to reduce the creation area available to employees and thus also costs.
Space Monitor
Diagnosis includes analyzing and identifying inefficiencies, unnecessary losses, bottlenecks, or budget overruns. Furthermore, in addition to initial diagnosis, IWMS software can evaluate and continuously improve processes to increase productivity and customer or user satisfaction.
Decision Support Made Simple
It is becoming increasingly important for managers of organizations to be able to make informed and quick decisions. To do this, they must be able to rely on data that is accurate, comprehensive, reliable, and quickly available.
If they have an integrated workplace management solution, all this data is available to them thanks to various types of reports, analytics, and dashboards. They can even access forecasts to help them make a decision.
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Cut Costs
All of the above benefits have an impact on cost. While it's hard to quantify them all, some studies show a 10-15% reduction in facility costs, a 5-8% reduction in process costs, and a 5-8% reduction in rental costs. Typically, building stock and installation costs can be saved by 10% to 20% due to data control and transparency.
By purchasing an IWMS software solution, a business or organization can make significant advances in space organization and management and significantly reduce its operating costs. This approach needs to be prepared, built, and shared in order to maximize its effectiveness by choosing the right tools and involving all future users. Consider reading, how can CMMS software save you money.
Hybrid Work And The Evolution of Facility Management Software
Facilities management solutions have changed dramatically over the past few decades - even more so in recent years. Especially due to the emergence of hybrid working, IWMS software has also become one of the most valuable new technologies in the workplace. Of course, hybrid offices are becoming more and more common in today's world. The management of their workplaces has also become increasingly demanding.
Today, FMs are often tasked with improving the workplace experience, improving space utilization, and/or introducing flexible work arrangements such as hot-desking or hotel-style offices. To do this, they need to be able to quickly and easily update floor plans, as well as collect and aggregate data on how the workspace is actually performing. In other words, you need a state-of-the-art IWMS solution.
CAFM vs. IWMS: What's the Difference?
Computer Aided Facility Management (CAFM) software typically focuses on a unique perspective of space and asset management - fully optimized for facility management and integrated to some extent with workplace service requests. This is ideal for smaller businesses and facilities that don't need more complex management software and prefer to just manage services and track requests. CAFM programs also tend to span multiple platforms, not just one.
IWMS solutions are ideal for large organizations and enterprise-level companies that monitor multiple areas of management. These systems exist on a single platform that facilitates demand management, planning ideal strategies, managing energy and resources, capital projects, real estate, lease management, and facility maintenance.
The Future of IWMS Solutions
As jobs become more complex, you can rest assured that your IWMS solution can keep up.
As we've already mentioned, the world is moving to more complex work arrangements. Not surprisingly, the best IWMS solutions help simplify this complexity and make dynamic spaces more manageable.
Hybrid and distributed work are harder to optimize and harder to see what's really going on in your workplace.
Additionally, IWMS systems can be expected to increasingly take on the task of improving the employee experience.
For example, helping employees book the right type of workspace can help remove barriers to productivity and engagement.
IWMS software solutions are a convenient and hassle-free way to track and manage every element of your facility and business with a single facility management system. It is easy to use and flexible enough to adapt to the growing and changing needs of your business. While there's nothing wrong with computerized facilities management software, your business may need more. This is where IWMS software comes in, providing a way to track and manage workplace management more efficiently.
In summary, IWMS is a powerful tool that can be customized to meet the specific needs of your organization. Enjoyed reading this blog? Consider reading, why your CMMS may not meet expectations.
CMMS
Why Your CMMS May Not Meet Expectations
CMMS software 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.
But – implementing a CMMS correctly means making the most of your investment. To do this, you need the know-how and experience necessary to avoid nasty surprises when it will already be too late.
Implementing a CMMS requires planning, time, and project management skills that will involve people and processes within your company.
Being able to do it well means starting the journey towards better management of your resources on the right foot, which will potentially be studded with great satisfaction.
For this to happen, it is not enough to choose the CMMS based on its functions. You need the know-how and experience necessary to ensure that the software can adapt to your processes, without expecting the opposite to happen overnight. The people involved need to learn how to use it and do it well, to get the most out of the system and not just a slice of the pie.
Your company is not only making an investment in terms of money and time, but it is also facing a cultural change, as it moves from an old way of doing things to a new and more performing one.
What Is A CMMS Software?
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 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.
What Does CMMS Software Do?
The CMMS is a software capable of containing all the maintenance information: from the technical master data to the asset files, passing through the maintenance plans, the requests for technical intervention, and the work orders. It also allows you to manage all the documentation, the history of interventions and work reports, the spare parts in the warehouse, and 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 the same, 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. Read also, 20 benefits of CMMS tools for small business
How Does It Work?
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 check-lists to ensure that the interventions are carried out in the correct way and finally assign them to the person indicated on the basis of the machinery or its location.
This allows you to drastically reduce costs and management times of your resources, in addition of course to 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 in the field at all times. They will be notified via a simple notification (or an email) when a work order is assigned to them, they will be able to consult the documentation, record the intervention times, take advantage of the check-lists attached to the work order, and add the pieces in just a few taps spare parts used in the final report. See also, what is CMMS? Features, benefits, and how it works.
What Does This Mean?
This will allow them not only to cut intervention times but also to automatically record all the data and information relating to the work order within the CMMS system. Once the intervention has been completed, they will be able to automatically generate the end-of-work report, form it directly on their telephone, and send it to the system (as well as by e-mail to the interested figures).
At this point, the CMMS system records the data and orders them within the platform, where they will be available in real-time.
Similarly, the maintenance manager will have a complete view of the progress of maintenance operations, and 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. Consider reading, 10 easy steps to successful CMMS implementation.
Why Set Up a CMMS Software?
A CMMS software brings to the company or organization:
better productivity (plan and manage maintenance interventions, centralize information for technicians, prioritize requests and tasks, etc.);
improved cost control (greater durability of equipment thanks to regular maintenance, anticipation of expenses to find the best price);
more transparent and more fluid communication of information between the various managers of a structure and their clients;
automatic reporting in the form of dashboards and statistical reports, with high-level traceability.
The CMMS is also a guarantee for the continuity of a company's activity. It limits the risks in terms of equipment failure or out-of-stock.
In the absence of a dedicated IT tool, maintenance management within a company or another organization runs the risk of being neglected. A human-made error, such as a simple oversight to order new stock or update a workstation, can cause chain reactions and hurt a team's overall performance. Read also, a step-by-step guide to choosing and using the right CMMS.
Why Do CMMS Implementations Fail?
According to a study, by one of the most authoritative voices in the maintenance industry, between 60 and 80% of CMMS software implementations fail.
The main reasons for these failures are:
Lack of clear goals
Lack of a figure able to lead the project
Insufficient training and post-implementation support
Inability to tailor the software to business needs and practices
Solutions developed in-house without the necessary know-how
Most of these motivations have something in common. In fact, they do not concern the product itself, but problems of various kinds that arose during the implementation process.
This is an important food for thought, to keep in mind when we are about to choose a CMMS. There are not only functions and indeed, in this regard here is another interesting fact, relating only to the American market: according to Reliable Plant, 90% of companies that use a CMMS do not take full advantage of its characteristics. See also, CMMS success, top 7 industries that benefit the most.
Why Your CMMS May Not Meet Expectations
The reasons why CMMS fail are as varied as the companies that implement them. Often the software package chosen or the manufacturer support provided is to blame. But that's usually an excuse, not the real reason these errors occur. Failure can usually be traced to one or more of the following main causes:
Solving the wrong problem with a CMMS
Sometimes, companies decide to implement a CMMS to solve problems that are not related to the system. For example, you might hold on to inappropriate or outdated maintenance practices; or they neglected training in the past, or the organizational structure isn't right for doing business in today's environment. Unless these problems are addressed, no system will help and actually make the problems worse. Before starting a CMMS project, make sure the problem is properly defined.
Lack of organizational goals
Realizing that you need CMMS software is an important first step. Next, you should decide why you want it and what you expect from it.
If you don't have a clear roadmap, it can be difficult to understand exactly what steps are needed to complete a project. Set clear goals for yourself from the start:
How the implementation process should work
How your team will use the software
What role will your staff play in the process
Avoid filling your team with ambitious plans. Keep realistic expectations and easy-to-achieve plans. This is the best way to avoid burnout and make sure everyone shows up as expected. See how to maximize manufacturing production with CMMS.
The wrong package was selected for the job
Often a CMMS package is chosen that is not suitable for the desired solution. For example, the features and functionality of a software package may be suitable for rolling stock maintenance but not for a processing plant with a large amount of capital equipment. Mismatches between system capabilities and solution requirements are often the result of a rigorous process of evaluating and selecting packages to meet solution requirements was not followed.
Insufficient change management
Among the top reasons for project failure, change management is the most overlooked. However, effective management of organizational change is critical to the long-term success of a CMMS project. Change cannot be left alone. It must be planned and executed carefully.
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Four Reflections On The Benefits Of A CMMS Software
The following is not an exhaustive list of the benefits that CMMS software can bring to the maintenance of a company.
Instead, it is meant to be an invitation to reflect on some of the main aspects, which together can have a disruptive effect on the entire corporate maintenance process.
Improve workflow
One of the most important effects that a CMMS (Computerized Maintenance Management System) can have on maintenance management concerns the workflow.
A CMMS software is a real hub, capable of intercepting and connecting the various maintenance processes, from the opening of a ticket (therefore a request for intervention) to data analysis.
In between are the management of work orders, technicians, and suppliers, planning of preventive maintenance activities, monitoring of assets and downtime, maintenance management, and warehouse management. And so on.
With CMMS software, managers, technicians, suppliers, and customers are able to collaborate all together and in real-time, with different levels of access, on the same platform.
So we can say that maintenance is in one place.
Now think about your processes. How well are they able to integrate with each other? What advantages could it bring, in terms of workflow management, and data flow, or what impact could it have on intervention times?
Communication
Collaboration is a central aspect in maintenance management and therefore also in the implementation of a maintenance CMMS. Optimizing communication between the actors involved means:
Improve productivity
Improve efficiency
Decrease errors
In addition to eliminating errors, CMMS software is also able to remove obstacles, slowdowns, inaccuracies, and loss of productivity largely due to communication problems.
A great way, often underestimated, allows you to save time and therefore money.
Think about your maintenance processes. How does communication take place between the subjects involved? Do you use email, WhatsApp messages or phone calls? What are the limitations of these means compared to the automatic tracking and monitoring provided by a software CMMS?
Simplification
Other benefits of a CMMS are the different aspects and functions that can usually contribute to simplifying maintenance processes through:
Traceability: The complete traceability of all the single actions that are carried out on an asset, a plant, a machine, or inside a building, is a fundamental aspect.
With CMMS software, all actions are recorded automatically within the platform.
This not only allows maintenance events to be traced but also makes this information easily accessible thanks to automatic entry into the maintenance system.
Automatisms: The creation of automatisms allows us, through guided procedures and automatic compilations, to avoid errors, for example on an intervention request, but also to save precious time in the operations planning phase or in the creation and assignment of work orders. For example, we can automate the creation of a work order whenever a plant or asset reaches a certain condition, based on triggers such as time, mileage reached, or meter monitoring.
Documentation: The creation of a digital profile of our assets, plants, and buildings allows us to access all the related documentation with a simple click: guarantees, contracts, but also the history of interventions, saved checklists, maintenance, etc.
Maintenance plans: A great classic of CMMS software. Establishing priorities, and correct strategies, and evaluating their effectiveness is one of the fundamental aspects of a maintenance management program.
Data
Finally, the data.
We have a budget available, often quite tight, and we have to respect it. So we want to make sure we allocate our resources as efficiently as possible.
Are we doing too much corrective maintenance? Or too much preventative maintenance?
How much does downtime cost us?
Are we spending too much on a particular asset and perhaps it would be worth replacing it?
When is the best time to carry out an inspection?
Which supplier guarantees us the best results?
These are just some of the questions that CMMS software allows you to find answers through analytics, economics, and the creation of customized reports.
Data analysis is the key to maintenance management systems. Using CMMS software to manage maintenance, means knowing your processes and finally making them measurable.
How To Choose The Best CMMS Software And Meet Your Expectations?
Choosing the best CMMS for your company is a delicate operation, which not only requires careful evaluation but can turn out to be a strategic decision of no small importance.
Nowadays the market offers a wide range of different CMMS solutions, starting from the choice of a cloud or on-premise software.
But functions are not the only aspect to consider. Implementing a CMMS is a delicate matter that needs a lot of attention.
Very often the best solutions are also linked to services such as training and education, as well as the availability of a project manager made available by your supplier who is able to transfer the necessary know-how, together with the identification of objectives and steps necessary for the implementation to be successful.
Furthermore, the possibility of customizing the CMMS software to adapt it to your processes and workflow always proves to be a fundamental discriminating factor, which no successful implementation can ever ignore.
In other words, the saying "do it yourself, do it for three" does not apply when it comes to a computerized maintenance system. If you found this useful, consider reading, essential tasks to track in your CMMS.
Here are some aspects to be clarified during the analysis phase to help you choose the best CMMS based on your real needs:
Does the vendor you've selected also offer the necessary services for implementation?
Does the CMMS feature cover your needs?
Are your company goals aligned with the software offering?
Does the supplier provide someone who can lead the implementation within your company?
Is the CMMS you have selected able to guarantee the usability you need to make it easier for the whole company to adopt the software?
Does the supplier already have valuable experience in your industry, so they know what your needs are and bring in the necessary know-how?
Is the timeline for implementation clear and in line with your needs?
Meet Your Expectations With CMMS Software
The use of CMMS software in carrying out maintenance activities proves to be a fundamental card for anyone who wants to raise the bar of their productivity.
In fact, digital maintenance management allows you to save time, save money and increase the efficiency of maintenance teams, as well as the performance and life cycle of company assets.
This is why CMMS software is a tool capable of making a difference, part of a digital transformation strategy that companies can no longer postpone.
Naturally, however, to fully reap the benefits of using such a tool, it is necessary to consider maintenance and its processes as part of an investment that aims to save us money, make our plants more productive, increase safety at within the company, and enhance the assets we have, instead of considering it (as has been done for too long and still today, unfortunately, in some circumstances) a due cost.
CMMS
The Future of CMMS: Trends and Predictions
The Future of CMMS as we know it will continue to change and improve as more and more companies continually strive to achieve better resource allocation, greater customer satisfaction, optimized production, and improved safety performance.
Development Of Different Generations Of CMMS
CMMSs have been around since early computers. In the 1960s, the first generation of maintenance solutions used punched cards running on IBM mainframes. Earlier versions of the app were limited in terms of usage and the expertise required to execute basic work orders. The system has attracted large corporations and government organizations to manage its service operations.
Punched cards were replaced by computer terminals in the late 1960s. The development of mainframe computers made the solution available to many organizations, but it remained limited to large corporations and government organizations that could afford the tool.
After the introduction of minicomputers in the late 1970s, service management continued to evolve with advanced features that enabled medium and large industries to take advantage of CMMS. Technological advances in personal computers from the late 1980s to the early 2000s paved the way for the platform.
CMMS and Internet Access
The possibility to connect a PC to a local network expands the range of use of the tool's functions. After the 1990s, and more precisely from 2000 onwards, we saw a huge growth in maintenance driven by the internet and the cloud. This is the story of how CMMS evolved and achieved its biggest breakthrough, which can be used anywhere in the world with Internet access.
This solution emerged through service operations in various industries and evolved from a buy or support model to a SaaS model. After the outbreak of the Fourth Industrial Revolution in 2010, computer networking capabilities emerged. With the advent of wireless and cellular technologies, cloud-based solutions are adopted. Here, the on-premises application model is replaced by a cloud-based model. With the development of Industry 4.0 technology, mobile service solutions have become common, and the Internet of Things and artificial intelligence have made important contributions. This makes it easier for users to remotely place work orders, track progress, and order parts.
The Evolution Of CMMS
The development of CMMS is relatively new, around 50 years ago.
From on-premises CMMS to cloud CMMS.
Initially, there was no wireless or cellular access, so the use of CMMS was limited to large punched card computers. For the most part, these early systems were only attractive to very large companies, given the cost of the equipment and the expertise required to operate them.
With the advent of computer networking capabilities, CMMSs have evolved. They are then available on the institutional network and can be accessed from a desktop computer. With the advent of wireless and mobile technology, the cloud-based CMMS format made its debut. Another new feature of the software is mobile access, allowing system users to remotely place work orders, order parts and track progress.
Finally, the introduction of predictive maintenance programming represents a quantum leap forward for facility management, allowing regular maintenance checks to be performed while equipment is still operating and with minimal disruption to the manufacturer's production cycle. All of these developments make the latest CMMS releases more attractive to companies of all sizes and industries.
Maintenance management today.
Today's maintenance management experience is very different from that of a spreadsheet user or earlier CMMS versions.
Automation. Once implemented, these systems perform all maintenance management tasks automatically and often require little more effort from the user than a click or touch of the equipment being used. Maintenance technicians no longer need to be burdened with paperwork as all labor and parts orders, job tracking, and other communications are done electronically.
Mobile access. Mobile access with camera and barcode scanning enables technicians to work from anywhere while saving time and reducing errors.
Customizability. Finally, one of the greatest benefits of today's CMMS is that they adapt to the organization, rather than requiring the organization to adapt to the system. This means they can meet the unique needs of large and small businesses with varying numbers of assets, users, locations, and preventative maintenance needs. Most importantly, they are also able to adapt to the changing needs of the organization as it grows and restructures.
Changes in technology, the market, and the business environment have all led to the development of CMMS as the solution of choice for maintenance management. By comparing pre- and post-implementation approaches to maintenance management, one can see how these software systems have helped thousands of manufacturing companies keep up with tighter profit margins and growing economic and industrial demands.
CMMS Top Trends And Predictions
The CMMS market is expected to grow at a compound annual growth rate (CAGR) of 9.1% from 2023 to 2033, reaching USD 42.15 billion. As CMMS software grows and becomes more widely used, predicting the future of CMMS industry trends can be challenging. However, we have identified some emerging trends that are likely to impact this market in the future of CMMS.
Gain better maintenance insights through big data
Almost every industry is leveraging big data to gain insight into its processes, predict problems before they occur, and then use that information to drive continuous improvement. From healthcare to aerospace, education, and manufacturing, these changes are happening primarily on Industrial Internet of Things (IIoT) platforms and wireless sensor networks.
We expect that within the next few decades, the maintenance process will completely shift from paper-based or manual management to real-time monitoring based on machine-provided information. The future of CMMS will be largely digitized and automated, with most of their decisions based on real-time machine data.
The overall result of this massive data analysis will be higher device reliability than ever before.
Cloud maintenance
The use of cloud computing solutions by businesses and individuals has increased significantly in recent years.
For maintenance professionals, the main benefit is that cloud-based maintenance support or maintenance-as-a-service offers comprehensive functionality accessible from anywhere in the world. The most popular of these tools are cloud-based computerized maintenance management systems (CMMS) because they offer customizable capabilities, can be deployed faster than on-premises CMMSs, and have traditionally provided more mobile, flexible, and customizable Enterprise Maintenance Solutions. Plus, it gives you all the benefits of a pay-as-you-go enterprise maintenance solution.
Prescriptive maintenance
Yes, predictive maintenance (PdM) is cutting-edge technology. But what about prescriptive maintenance? Prescriptive Maintenance (RxM) is a technique that analyzes machine data and uses that information to recommend actions to correct any anomalies and reduce operational risk.
Basically, RxM is higher than PdM. PdM tells us when something might go wrong, while RxM tells you what steps need to be taken to fix the problem.
While prescriptive maintenance clearly has the potential to fundamentally change maintenance, research is still ongoing.
Increasing Predictive Maintenance (PdM) Strategies
Advances in machine learning (ML), artificial intelligence (AI), and the Internet of Things (IoT) enable the collection of data from machine-level sensors and ML algorithms to predict machinery failure modes before they cause costly downtime. This process helps companies plan maintenance proactively, streamline maintenance operations and reduce operating costs.
The latest research reveals that the global predictive maintenance market was valued at USD 5.6 billion in 2021 and is expected to grow to USD 64.25 billion by 2030, at a CAGR of 27.4% from 2022 to 2030.
As the benefits of predictive maintenance are increasingly recognized, this maintenance strategy is expected to gain popularity and impact the CMMS market in the coming years.
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Internet 4.0, Internet of Things, and Artificial Intelligence
The use of modern tools such as Internet 4.0, artificial intelligence, and the Internet of Things is bringing the future of CMMS to industrial maintenance automation. Artificial intelligence or the ability of machines to self-regulate to maintain the human element, the CMMS must be able to integrate with these autonomous machine parts.
A computer can communicate with another computer through Internet 4.0 without human intervention. Smart devices can monitor themselves; no technician is required to do this. Maintenance managers have access to real-time data, which they can then take appropriate action to prevent unforeseen issues.
Companies use IoT data to manage asset maintenance. Predictive maintenance is used to make real-time asset management decisions. The maintenance function will be transformed from a cost center to a profit center. Using data collected through IoT, you can make decisions that align with your long-term goals. People are moving to data-based intuitive maintenance. Maintenance audits can be performed faster using IoT.
Inventory management
Additionally, to prevent unplanned downtime and loss of production, maintenance managers must ensure that spare parts and components are readily available. Therefore, one of the latest developments in maintenance management is the improvement of inventory management.
Modern CMMS systems make inventory and spare parts management easier than ever. With a reliable CMMS software solution, maintenance managers and technicians can determine which equipment requires which spare parts, provide an estimated time frame for when components on a machine will need to be replaced and more.
A data-driven approach to inventory control can eliminate waste, speed up item delivery, increase prices, and ultimately improve maintenance control.
High demand for integration with other business applications
In the past, CMMS software was seen as a tool that only benefited the maintenance department. These benefits are short-sighted and primarily seen as a tool for tracking preventive maintenance and spare parts. However, companies today are realizing how a CMMS fits into an organization's overall strategy. Obviously, if production machinery or critical equipment is unavailable, production will slow down or customer service will be disrupted. This ultimately affects the company's ability to compete and provide value to customers.
Since CMMS software is now considered a critical tool for achieving business goals, there is a strong need for integration with other business-critical applications. Many companies integrate CMMS with enterprise resource planning (ERP), customer relationship management (CRM), human resource information systems (HRIS), and other tools. CMMS users will demand integration capabilities with other business applications, and CMMS vendors are addressing these needs.
Automation and robotics are revolutionizing maintenance work
Automation technologies, including robotics, will play a vital role in the future of CMMS maintenance management. Robotic and autonomous systems will perform routine tasks, inspections, and repairs in hazardous or hard-to-reach areas, keeping maintenance personnel safe. These AI-powered bots will be able to analyze complex data patterns, detect anomalies and perform advanced diagnostics. Collaboration between humans and robots will simplify maintenance operations and allow technicians to focus on complex problem-solving and decision-making.
Using robots in maintenance management brings several advantages. They can operate in harsh environments without the need for personal protective equipment, minimizing risk to human workers. In addition, robots can work continuously without getting tired, thereby increasing productivity and reducing maintenance costs. By taking on repetitive and mundane tasks, robots free human technicians to engage in more strategic and value-added activities.
Robotic process automation (RPA) will also play an important role in maintenance management. RPA uses software robots to automate manual and repetitive tasks, such as data entry and report generation. By automating these administrative processes, organizations can increase efficiency, reduce errors, and free up resources for more important maintenance activities.
The CMMS Market Continues To Grow
The CMMS market is expected to continue growing through 2023 as more companies realize the benefits of using these systems to manage their maintenance processes. CMMS systems support businesses to increase efficiency, reduce downtime and increase equipment reliability, resulting in cost savings and improved profitability. The continued development of new technologies, including predictive maintenance and advanced analytics, will help drive further expansion in 2023.
According to a new study by Grand View Research, Inc., the global computerized maintenance management system market is expected to reach USD 2.41 billion by 2030, growing at a CAGR of 10.9% from 2023 to 2030.
The future of CMMS maintenance management promises exciting advancements driven by technology and sustainability. AI, IoT, automation, AR/VR, and data-driven decisions will revolutionize maintenance practices, increase efficiency, reduce costs, and increase equipment reliability. Companies that start using these technologies and invest in upskilling their employees will gain a competitive advantage in the future of maintenance. By integrating sustainable practices and circular economy principles, companies can contribute to a greener future while simplifying maintenance operations. The journey to the future of maintenance management and CMMS have already begun.
CMMS
Maximizing Asset Lifespan with CMMS
Maximizing Asset Lifespan with CMMS - As an entrepreneur, you're looking for ways to maximize profits and minimize costs. One of the keys is proper wealth management - an often overlooked aspect of running a successful business. By implementing an effective maintenance and procurement strategy, you can extend the useful life of your assets and save your business money in the long run.
The foundation of any business is your asset. In the current economic climate, there is no room for downtime, lost productivity, or poor quality. Maintenance teams are valued for their ability to keep assets running, while businesses seek to extract as much value as possible from their assets. Therefore, companies need to invest time in asset management (CMMS).
What Is An Asset?
An asset is an item of value owned by an organization or individual. Assets are divided into tangible assets (physical assets such as land and machinery) and intangible assets (information technology assets such as copyrights, trademark rights, and computer software).
Within tangible assets, there are two subcategories: current assets (cash, inventory) and fixed assets (equipment, buildings, machinery, and other physical resources used in the operations of a business that are unlikely to be sold). When we talk about asset lifecycle management, we're talking about managing the lifecycle of fixed assets.
What Is Asset Management?
Asset management in the financial industry is related to investment management. Digital asset management is a solution for storing and organizing media files. Asset management in an industrial environment is the process of maximizing the value of assets most economically during the life cycle of a company. In asset management, "asset" refers to everything tangible, including machines, buildings, cars, tools, and real estate.
Why Asset Management Matters?
Asset management is critical to any business, regardless of size or industry. At its core, asset management involves the maintenance and procurement of equipment, machinery, and other physical assets to ensure they operate efficiently throughout their lifecycle.
Proper asset management can help businesses save money by reducing downtime from equipment failure and minimizing repair costs. It can also extend the useful life of assets beyond expectations without regular maintenance.
Additionally, effective asset management improves workplace safety by identifying potential hazards before they occur. By maintaining accurate records of all assets and tracking their usage over time, organizations can make informed decisions about when to upgrade or replace obsolete equipment.
In short, investing in proper asset management is a smart move for businesses looking to increase efficiency and reduce overall costs. With a sound maintenance and procurement work strategy, companies can expect longer-lasting assets that deliver consistent results day in and day out.
What Is Asset Maintenance?
Asset maintenance is the process of maintaining and repairing physical assets such as equipment, facilities, and systems to ensure they are in good working order and function as designed. This can include activities such as inspection, cleaning, lubrication, repair, and replacement, as well as implementing a preventative maintenance program to identify and resolve potential problems before they arise.
Effective asset maintenance is important for the following reasons:
It increases efficiency and reduces the risk of equipment failure or downtime.
Reduce the risk of accidents or injuries due to equipment or system failure.
Extend the life of your assets by helping you detect problems before they become more serious.
Reduce maintenance costs because you can identify potential problems before they occur.
Increased asset value, as well-maintained assets command higher prices when sold or leased. Get better prices when selling or renting.
Asset maintenance can be performed by an in-house maintenance team or outsourced to a professional maintenance company. The specific approach to asset maintenance depends on the type and size of the asset and the resources and expertise available.
Asset Maintenance Management vs. Asset Management: What's the Difference?
Although the name may be misleading, asset maintenance management strategies should not be confused with asset management strategies.
Although the two concepts complement each other, they are not the same.
Asset management is a management system that requires input from all departments involved in the business process (maintenance being one of them).
Every aspect of the asset lifecycle – from research to acquisition to disposal – is part of an overall asset management strategy. In this strategy, departments such as planning, production, maintenance, and accounting work together to assess each asset's cost management, value, risk, and performance.
Asset maintenance management focuses on performing maintenance activities and coordinating maintenance resources (including spare parts, labor, budget, etc.). The strategy can be viewed as a smaller, more defined component of wealth management.
Maintenance stems from the need to keep equipment running, update maintenance schedules, and control costs as much as possible. However, access to asset management is critical to achieving maintenance excellence.
If the goal is to optimize asset availability throughout its lifecycle, reduce repair costs, increase productivity, and comply with regulations, you must follow resource management principles to help define the best strategy to apply to each asset to achieve the end goal.
The better your asset management strategy, the lower the cost of maintaining it.
Life Cycle Management
Life cycle management refers to managing the entire life cycle of assets from acquisition to disposal. This can help businesses make more informed decisions about when assets need to be repaired, replaced, or disposed of, based on their condition and value.
Currently, these trends in asset maintenance focus on Maximizing Asset Lifespan with CMMS using advanced technologies and methods to optimize asset performance and value. By using these technologies and methodologies, organizations can reduce maintenance costs, increase efficiency and productivity, and improve safety and compliance.
What Are The Basic Components Of An Asset Maintenance Management Strategy?
An AMMS (Asset Maintenance Management Strategy) can be said to be truly effective when it enables you to monitor, manage and control the following five basic components that help fully characterize the assets held by an organization, namely:
Identification – Not all assets of a company can be managed and maintained in the same way. Therefore, it is essential to properly identify all assets for which you are responsible and define relative importance levels to choose the most appropriate maintenance strategy.
Location – To properly manage an asset, it is necessary to know its exact location. However, the company's resources are likely not all concentrated in the same place. Some organizations base their business on using mobile assets or resources spread across multiple regions. To more easily locate assets to manage, many professionals in the industry rely on GIS (Geographic Information System) and GPS (Global Positioning System) technologies.
Condition – Knowing the shape of an asset is critical to planning appropriate management, maintenance, and disposal strategies. Status information can be collected manually through visual inspection or direct monitoring through smart sensors.
Maintain – Depending on the nature, location, and condition of each asset, an appropriate maintenance plan can be developed. It is important to identify which are the most critical assets requiring preventive maintenance and which can be managed with simple corrective maintenance. Using a CMMS system (Computerized Maintenance Management System) will help to simplify and automate all maintenance management operations.
Cost – Plant performance tends to decline over time as operating costs increase. The right asset maintenance management strategy can maximize the useful life of resources and identify potential savings, thereby minimizing management costs.
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The Management Connector To Empower Your Corporate Assets
The increase in the complexity of the plants and the need to minimize downtime make it essential to have a great ability to coordinate and share and preserve knowledge.
It is no longer possible to base decisions on estimates or impressions but all questions relating to maintenance must be answered based on exact numbers interpreted through reports and talking graphs. The interventions can no longer only be carried out following a breakdown or scheduled but must be carried out in advance according to optimized predictive models.
IT support that acts as a connector and facilitator of management becomes indispensable for providing the right information at the right time, managing people, deadlines, and interventions, and providing decision support.
CMMS is an essential tool for keeping assets efficient, productive, and profitable. Fundamental for management, monitoring, archiving, analysis, and, in general, for supporting the entire decision-making process. It must be an easy and intuitive tool with an optimal user experience that allows easy adoption by maintenance personnel, a facilitator, and not a complication of the daily operations of maintenance technicians and production workers.
The CMMS is a driving force to increase communication between those who work in maintenance at all levels. One of the goals is to get people to share information and knowledge related to the operating process to be faster, more versatile, and work smarter and more fluidly.
The CMMS is a technological tool that enhances people's work by making it safer and more efficient.
The Importance Of CMMS
The use of maintenance management software is essential to effectively monitor and manage maintenance processes. Maintenance management software allows you to plan maintenance activities, including execution times and responsible employees, efficiently and ensure that they are performed promptly.
In addition, maintenance management software helps reduce maintenance costs and productivity losses. This software provides a detailed overview of system health, including failures and malfunctions, enabling technicians to identify root causes of problems and perform corrective or preventive maintenance.
Maintenance management software also allows you to manage your spare parts inventory accurately. Thanks to these software solutions, maintenance activities can be planned efficiently, the spare parts inventory can be managed accurately and maintenance costs can be reduced.
Features Of CMMS
CMMS must be designed with specific features to meet the needs of maintenance technicians and maintenance task managers. Among the important features are:
Planning and scheduling: CMMS allows you to plan maintenance activities based on system and customer needs. Planning can include scheduling maintenance tasks, allocating resources, and tracking progress.
Monitoring and reporting: CMMS allows you to monitor ongoing maintenance activities, resource levels, and system health. The reporting functionality allows you to collect detailed information on failures and malfunctions of the system, and to create detailed reports for the maintenance activities performed.
Warehouse management: CMMS allows you to manage your spare parts inventory accurately. This includes managing inventory, scheduling purchasing activities, and ordering spare parts.
Automation: CMMS helps automate maintenance tasks and minimize the need for manual intervention. This includes automatic scheduling of maintenance tasks, sending notifications to maintenance technicians, and automatic reporting.
Functions Of Asset Maintenance Management In CMMS
Key features of asset tracking in a CMMS include:
Asset Registration: Asset tracking in a CMMS usually starts with registering the asset in the system. This includes entering information about the facility such as B. make and model, serial number, location, and other relevant details.
Maintenance and Repair Tracking: A CMMS can be used to track the maintenance and repair history of any asset, including the type of work performed, parts used, and repair costs. This information can be used to optimize maintenance planning and extend asset life.
Asset Location Tracking: Used to track the location of each asset, making it easier to locate and transport assets when needed.
Asset Availability Tracking: A CMMS can be used to track the availability of any asset, including whether the asset is in use or available for maintenance or repair.
Performance Tracking: Used to track the performance of each asset over time, including metrics such as downtime and frequency of repairs. This information can be used to identify trends and issues that may need to be addressed.
Advantages of Asset Maintenance Management
There are several advantages to using a CMMS for asset tracking:
Improved asset visibility: CMMS asset tracking provides a centralized digital record of all assets, making it easier to locate and track their usage, maintenance history, and current condition.
Increased efficiency: By automating asset tracking and maintenance planning, a CMMS can help streamline asset management processes and reduce the time and effort spent on asset tracking and management.
Reduced downtime: By tracking equipment maintenance and repair history and proactively scheduling maintenance, a CMMS can help reduce the risk of unplanned downtime due to equipment failure.
Improved asset utilization: By tracking asset usage and availability, a CMMS can help organizations optimize asset utilization and use resources more efficiently.
Improved asset security: A CMMS can help organizations track asset location and usage, reducing the risk of theft or unauthorized use.
Cost savings: By simplifying maintenance planning and reducing downtime, a CMMS can help companies reduce maintenance costs and extend the useful life of assets.
Invest in Asset Management Software (CMMS)
One of the best practices to adopt when managing assets is to invest in CMMS (Computerized Maintenance Management System) software that supports the most critical asset management needs. A robust CMMS system provides a central database for storing supplier information, warranties, site leases, and more. It will also provide tools to simplify maintenance workflows.
Overall, deploying an asset-tracking CMMS can help organizations improve the efficiency and effectiveness of asset management processes, reduce costs, and maximize asset value. CMMS asset tracking provides the current status of assets, providing vital information for your company.
Asset tracking is very helpful for CMMS software to make maintenance operations more efficient. Choosing the right CMMS software system for your company's maintenance needs is always crucial.
And remember, if your team doesn't have the bandwidth to harness this powerful tool fully, there's always the option to hire a part-time to manage it. This way, you can get the most out of CMMS without overstretching your internal resources. Don't let the complexities of CMMS deter you—it's an incredible asset optimization tool you shouldn't miss.
CMMS
How to Optimize Your CMMS for Asset Tracking
Asset and inventory management processes add unique value to operations by providing a reliable framework to track individual consumables, industrial equipment, and other critical assets. Assets are defined as equipment used to run a business, while inventory consists of finished goods or parts used in manufacturing.
Asset tracking doesn't have to be a nightmare. It can be a streamlined process that gives businesses a clear understanding of the location and status of their assets. All you need are the right tools.
What Is An Asset?
An asset is an item of value owned by an organization or individual. Assets are divided into tangible assets (physical assets such as land and machinery) and intangible assets (information technology assets such as copyrights, trademark rights, and computer software).
Within tangible assets, there are two subcategories: current assets (cash, inventory) and fixed assets (equipment, buildings, machinery, and other physical resources used in the operations of a business that are unlikely to be sold). When we talk about asset lifecycle management, we're talking about managing the lifecycle of fixed assets.
Why Is Asset Tracking Important?
People usually do business to make money. Assets enable companies to do this. Businesses buy (or lease) assets at cost and use them to produce goods or services that generate revenue.
Assets are also a measure of a company's value. Money-making organizations continue to grow by adding new assets or optimizing the use of existing ones. A thriving business is an attractive opportunity for investors, who may inject additional capital into the business to help it grow.
How does maintenance management affect assets? The maintenance team is tasked with maintaining the company's assets. To do this, the maintenance team must have sufficient information about available assets, such as their location and condition. Armed with this knowledge, maintenance teams can develop maintenance plans to keep assets in optimal operating condition.
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.
CMMS Software: Managing Asset Data
A supporting component of a proactive maintenance foundation is the integration of CMMS (Computerized Maintenance Management System) software, which creates a database for all the information gathered from maintenance monitoring sensors throughout the enterprise facility. CMMS software creates a framework that guides owners and users on how to organize this related data and establishes an interoperability hierarchy to determine how this data impacts different plant operations. CMMS software enables maintenance professionals to figure out how best to respond to asset degradation or impending failure before productivity is fully impacted.
How to Use CMMS Software for Asset Management
Asset tracking is an essential feature for any business to maximize return on investment. Asset maintenance management provides clear data to strategically optimize a company's assets and equipment.
Why do you need asset management?
Plant maintenance is very important for industries with a large number of machines and equipment. Since these assets are often expensive and represent a significant portion of the capital investment, proper maintenance is critical to getting the most out of them.
What is a CMMS good for?
A Computerized Maintenance Management System (CMMS) is a business tool that centralizes maintenance information and simplifies maintenance operations. It acts as an asset management software that manages equipment maintenance, and work orders, tracks inventory, and stores various equipment asset information.
Asset management software capabilities in CMMS software help to proactively track and manage assets across a company's multiple locations, giving maintenance managers quick access to relevant information from any device whenever they need it.
Features of Asset Tracking & Management Software in CMMS
A CMMS has many functions that support asset maintenance management:
Asset Tracking
All assets of the organization are always tracked. However, it may not be economically feasible to keep track of every single asset all the time, so better to keep track of the more important assets. Organizations classify their assets into more and less important assets based on a variety of factors such as sensitivity, criticality, value, or compliance requirements.
Collect information
Track various information about the device such as B. Model number, date of purchase, warranty details, serial number, etc. This information also aids in system operations, recalls, maintenance, etc.
Track spare parts and consumables
It is also important to keep track of equipment reserves, such as parts suppliers, parts, and consumables required for various equipment. Organizations try to manage their facilities at the lowest possible cost and in the shortest possible time. To achieve this, there is a great benefit to combining records and providing the above-mentioned assets.
Get device maintenance history
Gathering and recording information about equipment changes, maintenance history, costs incurred, etc. is helpful when replacing equipment. The features and cost of old equipment can be compared with new equipment to make effective purchasing decisions. Likewise, the operational history of calibrations, changes, damage, etc. can be recorded in one place to simplify the verification process while searching for relevant information to resolve issues.
Asset Tracking Best Practices for Maximizing Data Accuracy
Here are nine asset-tracking best practices to follow if you want to simplify your asset management efforts:
Use unique asset IDs
Assign each asset a unique identification number or code for accurate and efficient tracking. This helps avoid confusion and allows easy retrieval of asset information.
Regularly update asset information
Keep an up-to-date record of asset details, including location, status, maintenance history, and any other relevant information that requires manual updates.
Leverage technology
Leverage asset tracking technologies such as barcode labels, RFID tags, or GPS tracking devices to automate data collection and simplify the tracking process.
Conduct periodic audits
Periodic asset audits are performed to verify the physical existence and condition of the assets against the recorded information.
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Implement asset movement controls
Establish proper protocols and approval processes for asset movement within the organization. This includes documenting asset transfers, tracking custodians, and ensuring accountability to minimize the risk of unauthorized use or loss.
Train employees
Ensure that all employees understand and apply established follow-up procedures.
Integrate asset tracking with asset management solutions
Integrate asset tracking technology with other related systems such as ERP or CMMS software. This is the best way to ensure seamless data flow, avoid duplicate data entry, and gain complete visibility into asset-related information.
Implement security measures
Protect assets from theft or unauthorized access by implementing security measures such as access controls, monitoring systems, or anti-theft devices.
Continuous improvement and optimization
Regularly assess asset tracking processes, identify opportunities for improvement, and implement necessary changes. This includes analyzing data, gathering employee feedback, and leveraging technological advancements to improve the efficiency and accuracy of asset tracking.
How Helpful Is Asset Tracking In Delivering Functionality Through The CMMS?
Tracking assets using digital technology changes business models as it offers new value-add opportunities that CMMS promises.
Asset Tracking helps organizations to perform various activities such as Maintenance Management, Purchase Requisition, Physical Inspection, Asset Scanning, etc. With asset tracking, a computerized maintenance management system can be easily implemented.
Customizable configuration
Asset tracking is very user-friendly as it can be customized according to business needs. You can also make adjustments and additions if necessary.
Inventory management
The maintenance team also manages inventory levels. Inventory can include extra machine parts, craft supplies, office equipment and materials; hotel bedding, room linens, etc.
CMMS software informs remaining inventory levels, quantities used during maintenance, and reordering of new material. Also, it helps in managing inventory efficiently and controlling inventory-related expenses.
Mobile platform for Asset Tracking
The asset tracking mobile app behind CMMS provides 24/7 access and convenience. If you want to know where your assets are, just use your smartphone and access the app software.
Mobile technology provides the opportunity to ask questions, solve problems, and ensure on-time operations. Search for updates and information even when users are away from their desks.
Preventive maintenance
PM is a periodic inspection program with the goal of "finding and fixing small problems before big ones arise."
It is an essential part of a CMMS because it can be scheduled in advance. It also sends out alerts and notifications to take over scheduled tasks.
The goal of preventive maintenance is to maintain the machine or equipment in the absence of breakdowns. This includes performing some or all maintenance, oil changes, lubrication, etc. at specified intervals.
Preventive maintenance can save up to 20-30% in maintenance costs.
Purchasing and Requisition
Procurement and requirements processes have also become more efficient in achieving consistent results. The digital procurement process is easy to set up because it is computerized and multiple operators are responsible for handling large amounts of data dynamically.
The purchase requisition process interfaces with the purchase requisition software in the asset tracking system to provide stock level notifications before stock levels reach minimum stock and backorders are required.
Required processes will be verified against relevant existing invoices and purchase orders before approval. Reports are generated without blocking and delays. So you have a real-time vision. Cloud-based storage is centralized with easy and seamless access to the system and approval requests.
Security check
Security is one of the least considered aspects. Unmaintained equipment or its sudden failure may result in personal injury. Fortunately, this situation can be avoided if the right precautions are taken.
Maintenance management software tracks maintenance and lets you know when the last maintenance was performed and when the next maintenance is due. A computerized maintenance management system allows supervised access to prevent safety hazards. The right people can access the application.
This also reduces insurance costs, since preventive measures aim to prevent accidents and injuries.
Work plan and arrangement
Many companies employ computerized software to manage their work orders and streamline their maintenance operations.
In the application, you can easily get detailed information about the ticket. Important data such as work order status, machine status, work order assignments, and work order history can also be retrieved.
Comparison of CMMS and EAM Asset Tracking & Management
Some companies use hardware maintenance software called CMMS, short for “computerized maintenance management system” but also called “computer-assisted maintenance management software”.
CMMS and EAM systems have similar goals and some of the same functionality, although EAM systems offer a wider range of functionality. What sets them apart is philosophy and scope.
A CMMS system focuses on support, while an EAM system takes a holistic approach, integrating multiple business functions. The CMMS begins to provide follow-up after the purchase and installation of an asset. On the other hand, the EAM system can follow the entire life cycle of an asset, starting with design and installation. A CMMS system is designed to handle a single site or offer limited multisite support. The EAM system is equipped with extensive functions to manage multiple sites and companies.
An EAM system is a comprehensive tool for managing physical assets and optimizing their performance across the enterprise. EAM is a CMMS combined with an inventory management system, a purchasing management system, a document management system, an accounting system, a project management system, multi-site management tools, and performance management, all in one integrated software.
Asset maintenance management is very helpful for CMMS to make operations simpler and more efficient. It simplifies asset management, makes company operations robust, and provides a comprehensive reference guide for the future. A CMMS enables management teams to make informed decisions based on operational efficiencies and asset cost savings, thereby increasing company savings.
Operations & Maintenance
Work Orders Guidelines – A Quick Guide For Every Industry
Work orders guidelines enable you to better organize and oversee your service activities, developing a proper work order greatly contributes to the efficiency of management teams and your field workers, and to smooth communication between all stakeholders.
What is a work order?
A work order is a document by which managers authorize workers to complete tasks. Also known as a work order or service order, work orders are commonly used to manage maintenance operations across industries. They can also be used for follow-up actions on inspections or audits carried out.
The importance of work orders
Work order guidelines are the heart of any maintenance management system. These are not only simple tools for planning and assigning tasks, but also for controlling the variety of resources spent on maintenance. Work orders are important because they play a vital role in standardizing maintenance workflows, including from submitting work requests to closing work orders.
Read also 6 steps to implement a work order process + guide.
What is a work order used for?
A work order contributes to good communication between the field teams, the management teams, and the customers, regarding the nature and the conditions for carrying out the maintenance task. It standardizes workflow and helps streamline the process of planning, assigning, and tracking tasks. It can be used to document resources and track performance.
Therefore, it is also a document with legal significance, which can serve as proof in the event of a customer complaint. Everything is reported there, from the exact schedules for performing the service at the place of its execution, to the equipment used.
In addition to this, the work order has practical utility for all parties involved:
For the technical team:
have the details of the intervention and previous ones, if any,
keep track of the hours worked,
have a document serving as an intermediary between the service provider and the client,
have the completion of the work validated by the customer's signature.
For the team leader or the service provider:
follow up on interventions,
have traceability of the interventions in case of disagreement with the customer,
collect reliable data on the hours worked by technicians,
be proactive about the maintenance services to be provided,
increase trust in the customer relationship,
grant more autonomy and responsibility to its teams, while adopting a posture of continuous improvement.
For the customer:
keep the history of the services obtained,
easily find the contact of the intervening company,
have the possibility of giving an opinion on the quality of the service received,
understand price calculation and invoicing through transparency.
How to make a work order?
What does a work order contain? There is no standard format because each document can be adapted to the company's specificities and needs.
Its layout is also very variable, it is above all a communication document so be sure to favor clarity!
Here is the list of the most common information that can be found here:
the number of the work order,
the date,
the place of intervention,
the coordinates and the contact of the customer,
the type of service,
the detailed description of the intervention,
the material used,
schedules: start and end dates/times,
the total hours worked,
the history of other interventions previously carried out,
attachments (photos, plans, diagrams, etc.),
any concluding remarks.
A few work orders guidelines:
specify the start/end times of the service,
add a photo of the work done,
specify the spare parts needed,
have the client sign to validate the intervention.
The difference between a work order, a work request, and a purchase order
While a work order is sometimes referred to as a work order or service order in other parts of the world, they are essentially the same thing. However, although related to each other, work orders cannot be used interchangeably with work requests and purchase orders, as each term has a different meaning:
Work order or work request
The difference between a work order and a work request is their source and sequence, i.e. where they originate from and when they are triggered. Typically, work requests come from people who are not maintenance personnel, which leads to the creation of maintenance work orders. For example, machine operators typically first submit a work request for an equipment problem, then maintenance managers approve a designated work order to mechanics.
Work order or purchase order
The difference between a work order and a purchase order is how they are used as part of maintenance work order workflows. While work orders detail specific tasks or services to be performed, purchase orders detail the materials or products needed to complete a work order. Typically, a work order includes a purchase order with the new parts and items to be used when repairing or servicing a piece of equipment.
Read also 10 steps for choosing the right CMMS.
Work Orders guidelines
There are several ways to create a work order, depending on business requirements and customer needs, among other factors. Either way, a streamlined process for opening work orders can ensure that maintenance work gets done on time. Below are some general work orders guidelines to help teams write work orders more effectively:
Understand the work required
Work order writers must not only refer to the details stated in the work requisitions, but they must also gain a thorough understanding of exactly what needs to be done. If in doubt or if some information seems vague, such as equipment symptoms and initial safety considerations, these should be confirmed with the applicant early on to avoid duplication of work.
Consider the resources needed
After having clearly identified the work requested, think about the elements necessary for its realization. Anticipating what tools to use, inventory to check and parts to purchase can help avoid costly delays. Also, it is essential to assess whether the task can be done alone, with another member of the maintenance team, or with colleagues from other departments like engineering and industrial design.
Be specific but succinct
A work order template contains the job description, recipient(s), requester details, cost breakdown, schedule or deadline, and authorized signatures. The key to effective work order writing is to present all the necessary information in a simple manner. Finding the balance between brevity and completeness can help minimize the risk of discrepancies when implementing the work order.
Set realistic estimates and deadlines
When breaking down the cost of labor, materials, and equipment for any job, state reasonable amounts. Asking too much or too little can potentially delay work order processing. Besides budget allocation, one of the biggest challenges of managing work orders is scheduling. Priority levels and due dates should be established based on technician availability, maintenance schedule, and other ongoing tasks.
Use work orders without resorting to paper
Work orders written on paper can be difficult for management to organize, as they tend to be easily damaged and misplaced. A digital work order form, on the other hand, can be filled out on any mobile device, making it easier for teams to write work orders wherever they are. Unlike traditional paper-based service orders, scanned work orders not only minimize data entry errors but also save time and effort when sending them out for authorization.
Sample Work Order System and Procedure
A work order system should allow employees to perform maintenance tasks more efficiently, not slow them down. To streamline work order processing, first, assess business performance using industry benchmarks. Compare your results with the example work order procedure below and identify areas for improvement in the context of the organization:
Step 1
Work request submission and review – Non-maintenance employees submit a work request which is reviewed by their manager. Their managers then validate it with the information entered during previous inspections before sending it to the maintenance department.
Step 2
Approval and creation of a work order – Upon receipt, the maintenance manager determines if the scope of work is necessary. Once approved, management records the work request in the form of a work order with their signature.
Step 3
Work Order Assignment and Scheduling – After giving permission, the manager assigns the job to a mechanic and schedules when it should be done. Applying a dispatch matrix can help ensure that the most qualified technician will be dispatched to work on a particular asset.
Step 4
Work Order Fulfillment and Tracking – In the equipment location area, the maintainer observes physical constraints, identifies environmental conditions, and prepares any type of notes that can help accomplish the work order. When resources become available, work can begin and the manager begins tracking the status of the work order.
Step 5
Work Order Completion and Record Keeping – Once the work is done, the service technician reports the work actually performed and his manager reviews it before closing the work order. Finally, the maintenance manager files the completed work order for future reference.
Conclusion
The work order is the written record that restores the information concerning work between a service provider and a client: what must be done, when, with what material and what labor, and for how much. It is essential in many industries, especially for service and maintenance companies.
For your organization to gain in efficiency and productivity, equip yourself with software to manage your work orders and benefit from digitized information exchanges: readability, reliability, security, and data traceability will be there, both for the workers in the field, their managers and the administrative and accounting departments. Use our Work Order guidelines to succeed.
Read also 10 steps for CMMS implementation.
Operations & Maintenance
Preventive Maintenance – What It Is And How It Is Done?
Preventive maintenance program, or planned technical maintenance, consists of intervening on equipment at regular intervals or according to predefined criteria. Its primary objective is to reduce the risk of breakdowns on goods, machinery, and equipment, but it also makes it possible to achieve more general objectives.
This is why most factories and companies seek to increase the share of preventive maintenance implemented compared to corrective maintenance.
To implement a preventive maintenance strategy or plan, it is important to master the main aspects and know which tools can be used.
Read also 10 steps for choosing the right CMMS.
What is the purpose of preventive maintenance program?
Maintenance is carried out according to predetermined criteria, the objective of which is to reduce the probability of failure of an item or the degradation of a service rendered. So, it must make it possible to avoid equipment failures during use. The cost analysis must highlight a gain in relation to the failures it avoids.
Purpose of preventive maintenance:
Increase the lifespan of equipment
Decrease the probability of in-service failures
Reduce downtime in the event of an overhaul or breakdown
Prevent and also plan costly corrective maintenance interventions
Make it possible to decide on corrective maintenance under good conditions
Avoid abnormal consumption of energy, lubricant, spare parts, etc.
Improving the working conditions of production staff
Reduce the maintenance budget
Eliminate the causes of serious accidents
What is the difference between preventive and corrective maintenance?
To summarize, we can say that corrective maintenance solves problems while preventive maintenance seeks to avoid them. Thus, corrective maintenance, sometimes divided between palliative and curative maintenance, occurs when a breakdown occurs on a machine or equipment. Preventive maintenance seeks, by means of checks and routine tasks, to verify that an item is functioning correctly and to identify any faults in its operation before it breaks down.
What are the different types of preventive maintenance?
There are 3 types of preventive maintenance:
systematic maintenance;
condition monitoring;
predictive maintenance.
Systematic preventive maintenance:
Preventive maintenance program is carried out according to a schedule established according to the time or the number of units of use (produced). Therefore, even if time is the most common unit, other units can be used such as the number of products manufactured, the length of products manufactured, the distance traveled, the mass of products manufactured, the number of cycles carried out, etc.
This frequency of an intervention is determined by commissioning or after a complete or partial overhaul.
This method requires knowing:
The behavior of the equipment
The modes of degradation
The average time for good operation between 2 failures
Cases of application:
Equipment subject to current legislation (regulated safety): lifting devices, fire extinguishers, pressure tanks, conveyors, elevators, goods lifts, etc.
Equipment whose breakdown risks cause serious accidents: all equipment ensuring the public transport of people, planes, trains, etc.
Equipment with a high cost of failure: elements of an automated production line, processes operating continuously (chemical or metallurgical industries).
Equipment whose operating expenses become abnormally high during their service life: excessive energy consumption, lighting by used lamps, improper ignition and carburetion (thermal engines), etc.
Condition-based preventive maintenance:
Preventive maintenance program is subject to a type of predetermined event (self-diagnosis, sensor information, wear measurement, etc.). Condition-based maintenance is therefore maintenance that depends on experience and involves information gathered in real-time. It is also called predictive maintenance (non-standard term).
The highlighting of weak points characterizes conditional preventive maintenance. Therefore, depending on the case, it is desirable to put them under surveillance and, from there, to decide on an intervention when a certain threshold is reached. But the controls remain systematic and are part of the non-destructive control methods.
All materials are affected. This conditional preventive maintenance is done by relevant measurements of the equipment in operation.
The parameters measured may relate to:
Oil level and quality
Temperatures and pressures
Tension and intensity of electrical equipment
Vibrations and mechanical play
Etc.
Some methods, such as vibration analysis or oil analysis, are very rich in terms of the information collected. Their understanding allows informed decisions to be made, which is the basis of conditional preventive maintenance.
Predictive maintenance:
Predictive maintenance consists of anticipating future failures on equipment, an object, a system, etc. Concretely, it is a question of anticipating a breakdown or a malfunction thanks to the accumulation of a set of data. Booming in recent years, predictive maintenance has had several advantages. It avoids, for example, the immobilization of a broken-down production system (with the resulting financial repercussions).
Read also 6 steps to implement the work order process.
So, predictive maintenance makes it possible above all to anticipate breakdowns and offers the possibility of intervening while avoiding a much more expensive repair. With predictive technology, maintenance costs are reduced by 10 to 40% and the number of breakdowns is halved. The savings generated result from several consequences:
Reduced breakdowns and therefore equipment downtime
Extending their lifespan
Improving the reliability of equipment and therefore optimizing production
Better spare parts inventory management
A reduction in maintenance costs.
Preventive maintenance operations
Inspections:
Monitoring activities consist of periodically noting anomalies and carrying out simple adjustments that do not require specific tools or stoppage of the production tool or equipment.
Visits:
Monitoring operations which, as part of systematic preventive maintenance, take place according to a determined frequency. These interventions correspond to a list of operations defined beforehand which can lead to the dismantling of components and immobilization of equipment. A visit may result in corrective maintenance action.
Controls:
Compliance checks against pre-established data followed by judgment. Control can:
Include an information activity
Include a decision: acceptance, rejection, adjournment
Lead, like visits, to corrective maintenance operations
Monitoring operations (checks, visits, inspections) are necessary to control the evolution of the real state of the asset. They are carried out continuously or at intervals that may or may not be predetermined, calculated over time, or the number of used units.
Conclusion
Start getting the most out of your assets and save money by pursuing a preventive maintenance strategy. Additional benefits: better organization and ongoing operations.
Although the adoption of preventive maintenance measures requires budgeting for regular service activities, in an industrial setting, it's usually worth it, especially since when an industrial operation is shut down for unscheduled repairs, it can quickly lead to production stalling or even loss of revenue.
Read also 10 steps for CMMS implementation.
Operations & Maintenance
Reactive vs. Preventive Maintenance – Long-term Cost Effectiveness
In facility management, most maintenance tasks are categorized as 'reactive' or 'preventive'. Knowing the difference between the two is important because the most successful facilities sectors maintain a healthy balance between reactive and preventive maintenance. Too much reactive maintenance can stress and overwhelm your team. Therefore, it is important to create a program that emphasizes preventive maintenance and minimizes the possibility of reactive maintenance.
In this blog, we explain the difference between reactive and preventive maintenance and their long-term cost-effectiveness.
Reactive vs. Preventive Maintenance
Maintenance is an important part of keeping equipment running efficiently for as long as possible. Maintenance inevitably involves downtime and expense, so maintenance is sometimes postponed in hopes of maximizing production and profits. This avoidance can be detrimental in the long run, so it is important to distinguish between preventative and reactive maintenance.
Preventive maintenance addresses potential problems before they occur and reduces the likelihood of unexpected equipment failures. Preventive maintenance involves cleaning, replacing parts, and inspecting equipment properly to identify problems and then fix them before they become bigger problems. Preventative measures are proactive and can improve equipment longevity and safety outcomes.
Reactive maintenance occurs after an equipment failure, often unexpectedly. Unexpected equipment failures can lead to increased costs such as more expensive repairs, overtime payments to repair equipment, and unplanned downtime.
Preventive Maintenance
Preventive maintenance software is a strategy that teams and managers employ before a failure or outage actually occurs.
The main goal is to reduce the likelihood of failure or deterioration of equipment, components, or spare parts. To perform this type of maintenance, the team must consider the history of the equipment and track its previous failures. This paves the way for determining how often equipment is likely to fail and require repair/maintenance.
Preventive maintenance is a planning strategy for maintenance operations as it is based on well-established maintenance facts, reports, equipment history, and needs of the organization working as efficient equipment maintenance software.
With preventive maintenance as part of the CMMS functionality, companies can easily organize their maintenance tasks and ensure continuous productivity.
There is no doubt that preventive maintenance is one of the most popular and effective maintenance methods. However, this may not always be the right choice, as each organization has its own idiosyncrasies. Sometimes the cost of preventive maintenance is much higher compared to other possible methods.
What Are The Different Types Of Preventive Maintenance?
There are 3 types of preventive maintenance:
Systematic Preventive Maintenance
Preventive maintenance is carried out according to a schedule established according to the time or the number of units of use (produced). Even if time is the most common unit, other units can be used such as the number of products manufactured, the length of products manufactured, the distance traveled, the mass of products manufactured, the number of cycles carried out, etc.
This frequency of an intervention is determined by commissioning or after a complete or partial overhaul.
Condition-Based Preventive Maintenance
Preventive maintenance is subject to a type of predetermined event (self-diagnosis, sensor information, wear measurement, etc.). Condition-based maintenance is therefore maintenance that depends on experience and involves information gathered in real-time. It is also called predictive maintenance (non-standard term).
Conditional preventive maintenance is characterized by the highlighting of weak points. Depending on the case, it is desirable to put them under surveillance and, from there, to decide on an intervention when a certain threshold is reached. But the controls remain systematic and are part of the non-destructive control methods.
All materials are affected. This conditional preventive maintenance is done by relevant measurements of the equipment in operation.
Predictive maintenance
Predictive maintenance consists of anticipating future failures on equipment, an object, a system, etc. Concretely, it is a question of anticipating a breakdown or a malfunction thanks to the accumulation of a set of data. Booming in recent years, predictive maintenance has had several advantages. It avoids, for example, the immobilization of a broken-down production system (with the resulting financial repercussions).
Predictive maintenance makes it possible above all to anticipate breakdowns and offers the possibility of intervening while avoiding a much more expensive repair. With predictive technology, maintenance costs are reduced by 10 to 40% and the number of breakdowns is halved.
Is Preventive Maintenance Cost Effective?
Preventive maintenance has long been the most popular maintenance strategy for manufacturers. In industrial maintenance, 60% of companies associate preventive maintenance with increased productivity and over 60% associate preventive maintenance with reduced downtime and increased safety. It has long been believed to provide better cost savings than reactive maintenance.
While preventive maintenance still involves machine downtime, it is scheduled for a more convenient time and preferred over unplanned reactive maintenance, where the cost and time until the problem is diagnosed and repaired is unknown.
Benefits of Properly Implementing a Preventive Maintenance Program:
Reduce maintenance costs
Depending on the type and complexity of the company's equipment, maintenance costs can be one of the largest financial drains. Preventive maintenance can help avoid this problem by reducing the likelihood of catastrophic failure or equipment degradation. Additionally, companies can now benefit from predictive maintenance software. These systems create regular maintenance checklists and help coordinate company-wide maintenance schedules.
Early detection of faults
One of the most basic preventive maintenance tasks is dismantling and thorough inspection of equipment and plant installations. While this is the most effective way to clean and polish your equipment from the inside out, it can also help identify some hidden flaws that surface diagnostics might miss. Production lines can benefit from early detection of problems as they are the cause of prolonged downtime. Regularly replacing dirty or partially damaged parts can eliminate many major defects in the long run. Managers can upgrade or install new functional software to realize automatic diagnosis and error detection. Additionally, some CMMS products can perform maintenance checks of an entire facility in a single cycle. Some systems are even building IoT infrastructure to incorporate device performance data. A single administrator can spot vulnerabilities before they cause significant damage.
Reduce downtime
For maintenance operations, both static systems and running machines must be partially or completely shut down. Preventive maintenance is almost always faster and uses fewer resources than other maintenance methods. Most modern operating systems, such as production lines and electrical equipment, include performance management sensors that identify specific problem areas. In this case, instead of shutting down the entire system, these problems can be isolated and fixed. With predictive maintenance, you can schedule maintenance work at convenient times, such as when employees leave the building or when the day's operations are over, reducing disruptions to production and efficiency.
Longer asset life
Every piece of equipment has a finite useful life after which it needs to be repaired or replaced to varying degrees. Companies typically purchase such assets after determining their potential operation and potential production. Most companies already factor in repair or replacement costs. Still, preventative maintenance can provide an extra layer of protection to prolong the life of your equipment. A preventive maintenance program ensures equipment is performing according to the manufacturer and consumer specifications.
Challenges of Preventive Maintenance:
May exceed expectations
With preventive maintenance, there is still a risk of over-maintenance. Some failures are less dangerous to your operation than others. If you dedicate resources to avoiding every single problem, you're probably wasting resources on PMs. Finding a balance between proactive error prevention and reactive remediation efforts is critical. If a preventative maintenance program is too extensive, it can lead to serious financial waste. In some cases, you should test components, parts, or even entire machines for possible failures.
Unexpected failure
Certain components and parts may fail randomly such that preventive maintenance cannot permanently prevent the failure. In such cases, it may make more sense to think about effective ways to deal with the consequences. You should not base the frequency of preventive maintenance calls on the usual metric of mean time between failures. Instead, the lifespan of the component should be considered when making this decision.
Continuous training for technicians
Another downside of some preventative maintenance systems is that field technicians don't always keep their knowledge and training up to date. The bottom line is, if your maintenance professionals don't understand the need for preventive maintenance, or aren't adequately trained to perform it, they won't be able to do it properly.
High upfront costs
When you first implement a preventive maintenance program, it can cost more to service equipment and assets on a regular basis than to wait for a power outage. Small businesses may find the initial cost of deploying a CMMS for preventive maintenance prohibitive if they have a limited budget for asset management and equipment maintenance.
Since facilities are regularly inspected for maintenance, you may need to invest in the latest tools and equipment to properly carry out the repair work, which will undoubtedly add to your overall business expenses.
Reactive Maintenance
Reactive maintenance is the strategy of returning equipment to normal operating conditions only when it fails. This means there is no regular maintenance or repair schedule to reduce downtime. Also known as breakdown repair or repair.
Under the right circumstances, reactive maintenance can be a good strategic approach. For example, you might have a facility that has low maintenance costs and is not essential to its operation. Or you may have planned to replace the machine after a failure, eliminating the need for proactive maintenance.
Reactive maintenance is a cost-effective approach as it requires minimal maintenance personnel and less budgeted repair costs. But it shouldn't be used as your long-term strategy. This can lead to increased repair costs, unplanned downtime, production delays and lost revenue. It is recommended to allocate only 10% of the total asset inventory to reactive maintenance.
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What Are The Different Types Of Reactive Maintenance?
In addition to various maintenance strategies, asset-intensive companies can also choose a strategic approach within this strategy. For example, preventive maintenance (PM) and condition-based maintenance (CBM) are forms of proactive maintenance strategies.
Reactive maintenance is an umbrella term that includes the following types of maintenance:
Emergency Maintenance
Emergency maintenance is performed on equipment or machinery that plays an important role in your production. This type of reactive maintenance is never planned and is usually a last-minute response to an immediate outage. Emergency maintenance also takes precedence over other business processes, which can cause unplanned delays.
Breakdown Maintenance
Similar to contingency strategies, breakdown repairs are unplanned events. It refers to an asset that fails suddenly and requires extensive repair work. This can lead to high repair and technician costs, as well as costly unplanned downtime. Running equipment to failure can cost organizations 10 times more than routine maintenance.
Corrective Maintenance
Corrective maintenance is a form of maintenance performed on an asset before it fails completely. For example, machine defects can be noticed during production. Rather than waiting for the inevitable machine failure, this part will be fixed immediately. Corrective maintenance is the closest thing to preventive maintenance in a reactive strategy by responding to problems before they escalate.
Run-to-Failure
Unlike the unplanned outage maintenance approach, run-to-failure maintenance is a planned strategy. This is done when the asset is consciously instructed to run until it fails. This allows a plan to be made to repair equipment without unduly delaying production. Or, in some cases, spare parts have been purchased to replace aging equipment should it fail.
Is Reactive Maintenance Cost Effective?
Reactive maintenance can be a fundamental part of any maintenance strategy, but when used alone it is only cost-effective for selected assets, such as:
Short-term assets.
Available assets.
Long-lived or unmaintainable assets.
Small capital assets.
Non-critical assets.
For most machines and systems, purely reactive maintenance is much more costly and the least efficient type of maintenance in the long run. That's because reactive maintenance can lead to unplanned inefficiencies and disruptions that often occur even at the most inconvenient times. Reactive maintenance is best used as a small part of a maintenance strategy once more efficient types of maintenance have been implemented.
Benefits of Reactive Maintenance:
Reduce investment cost
Reactive maintenance saves you money that would normally be spent upfront on preventive maintenance and labor costs. However, relying solely on reactive maintenance and completely ignoring preventive maintenance could be bad for your business in the long run.
Fewer staff required
With reactive maintenance, your main concern is to fix problems as soon as they arise. This way you don't need a huge team of technicians to manage the device all the time. For preventive maintenance, you must have at least two technicians in the facility to conduct timely inspections to catch problems early. This also translates into extra salaries, increased team size, and labor costs.
No planning required
Preventive maintenance requires planned machine downtime for inspections, parts replacement, and other maintenance activities. There is no planned or planned equipment downtime and reactive maintenance. However, this may lead to unpredictable equipment failures in the future.
Reactive Maintenance Challenges:
Overtime is more expensive
Late orders, damaged reputation, and lost sales are common consequences of unexpected delays in manufacturing runs. Additionally, the equipment can break down at inconvenient times when personnel and parts are scarce. In such cases, businesses may have to pay extra for after-hours assistance, commuting, and emergency parts.
Unexpected shutdown of equipment
Plant downtime is a major disadvantage of reactive maintenance, which can lead to plant shutdowns or production interruptions lasting several days. Downtime is especially problematic in manufacturing because it can lead to layoffs or even entire plant closures for an unknown period of time.
Employees work overtime
In addition to the initial financial loss that reactive repairs typically entail, you may also need to pay overtime for those responsible for the associated equipment. For example, if one or two employees use down machines more than others, they may need extensive knowledge of the broken machine when investigating repairs.
Reactive vs. Preventive Maintenance - Conclusion
In maintenance management, reactive maintenance and preventive maintenance are usually opposites. Choosing a plan for your business that fits your functions and needs can be a difficult choice.
Maintenance costs make up a significant portion of operating costs. Many unpredictable and uncontrollable situations arise, resulting in additional costs that are difficult to predict in advance but are closely related to maintenance.
But your equipment is the heart of your business. Neglecting to maintain your equipment can cost you a lot of time, money, and sometimes even your business. Maintenance management today is very different from that of spreadsheets, notebooks, pens, and paper. Businesses want to keep their existing equipment for as long as possible, they want to stay ahead of the competition, and of course, they don't want to suffer injury, equipment failure, or failure.
Is maintenance management important? If you consider your business important, maintaining your equipment and assets is equally important. You can't do it without equipment.
CMMS
Top 5 CMMS Features You Can’t Live Without
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.
Finding the right CMMS can be time-consuming and labor-intensive. You need to understand which Top 5 CMMS features will bring you the most value so you can focus on maintaining your equipment.
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 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. Read also, why your business might need CMMS.
The History Of CMMS
Its origins date back to the 1970s when industrial tools became more complex, with the transition from mechanics to electronics and the emergence of robotics. The industrial sector is becoming more and more demanding. The “zero breakdowns, zero defect” injunctions are everywhere. In the 1980s, it was computerization that transformed the maintenance professions. The first maintenance management programs appear. The 1990s marked the expansion of CMMS, which was no longer content to serve the industry, but also the tertiary sector. It was finally in the 2000s that CMMS software took off. And the web has something to do with it. With reduced hardware investment and reduced installation costs, the full web CMMS enters the scene and promises great capabilities in terms of ergonomics and functionality. Nowadays, in the era of the Cloud and galloping digitization, the user experience is enriched. A CMMS software package is essential for operational teams.
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.
CMMS: Who Is Affected By This Type Of Software?
The CMMS concerns several sectors of activity, as long as they involve maintenance of equipment, buildings, or installations. Here is a non-exhaustive list:
The real estate sector uses it to centralize information related to building maintenance.
The energy sector uses it in the management of network equipment.
The transport sector uses CMMS to monitor its infrastructures.
The public sector uses it in the management of public buildings in communities.
The medical sector uses CMMS for the maintenance of equipment, essential for medical operations.
The industrial sector uses it for the maintenance of automated machines.
Who Uses CMMS?
As said, CMMS software is a key tool for manufacturers, all sectors combined, who seek to maintain their production equipment in operational conditions.
Within the company itself, it serves:
Inevitably, industrial maintenance technicians are the first users of CMMS software.
The maintenance manager will also actively use the CMMS to monitor interventions, manage his stock of parts and monitor his budget.
Production teams can also use it to have visibility on past and future interventions.
The purchasing department can also refer to this tool for negotiations.
The logistics team will also have an eye on the CMMS to manage the stocks of parts and anticipate possible future supplies.
Top 5 CMMS Features
The CMMS (Computer-aided maintenance management) is a management software specially dedicated to companies in order to help them in the maintenance of their activities. This management tool includes many advantages, including five main ones, which have become essential for any company wishing to optimize its maintenance while reducing its maintenance costs.
Here is a zoom on these features!
Managing your equipment
With the CMMS, you manage your equipment in an optimal way. You can inventory and locate them with ease.
In addition, the CMMS allows you to manage information dedicated to each type of equipment. Whether production equipment, premises, vehicles, etc. you have easy management. This management also includes technical documentation, such as plans, or manufacturer documentation.
The CMMS software assists you by offering you the perfect knowledge of your equipment fleet. Thanks to the creation of this repository and the Full Web CMMS solutions, all your information is easily accessible to you internally and via the Internet.
Managing your maintenance
This is the second strong point of the functionalities of CMMS software. Thanks to the assistance of a CMMS, the maintenance of all of your company's equipment is guaranteed.
The CMMS allows you to manage both corrective and preventive maintenance. She can help you with:
Set up a new preventive plan based on past events,
Define the conditions for condition-based maintenance,
Log and trace each maintenance operation.
Managing your purchases
Regarding your purchases, the CMMS can save you money by taking charge of the purchasing conditions of your suppliers and allowing you to easily compare them with each other.
As for the integration of purchase requests into the CMMS software, it allows technicians and members of the maintenance department to have an optimal follow-up. They know at all times what the current orders are, with which suppliers, etc.
Stock management
For a company, CMMS software is particularly interesting for its inventory management features. Indeed, the software knows what quantities of products enter and leave the store, what parts are reserved for interventions, and what are the minimum and/or maximum quantities of replenishment.
The CMMS software also allows recording:
equivalent items,
supplier price catalogs,
links with the equipment tree,
Etc.
Managing your staff
The CMMS software also manages the workload schedules of your teams with planning assistance tools, as well as the provisional schedule of the work to be carried out. It also allows the monitoring of time spent by each speaker.
By assisting the maintenance department of your company, the CMMS provides you with considerable assistance and optimizes its productivity while reducing costs, in particular those related to the maintenance and upkeep of your equipment.
The five features above are the most common, but the CMMS includes many others, such as the management of regulatory controls, condition monitoring or the monitoring of key performance indicators.
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How to choose a CMMS software: advantages and features
To be able to have all the advantages listed up to now, it is essential to choose the right software that gives excellent work performance. Choosing it requires a preliminary study of the needs of a company and the objectives it wants to achieve over time, so as to be able to train and prepare personnel for its use.
How to choose a CMMS software: advantages and features are, in fact, important that all employees and insiders have a clear understanding of the functions of such sophisticated software and that it is promoted by all the managers of the organization.
The purchase of the software is an investment that changes the pace of work and consequently the coding systems on the plants.
The first consideration to be made will therefore be what specifications a CMMS software of this kind must have for the company under consideration; check the capacity of the software, understand which companies use it and their improvements, its congruence with any pre-existing software, the culture of the company personnel, who will need to be trained regarding the use of the new software.
With the help of CMMS, companies can control and manage production facilities, tools, and equipment used in daily operations. A software product must meet the following criteria to fall into the maintenance management system category:
Manage different asset types in multiple locations.
Maintain an inventory of required replacement parts, service tools, materials, and consumables.
Schedule maintenance tasks, including replacement, repair, and inspection.
Control and distribute labor and spare parts for maintenance activities.
Provides reporting and analysis on machinery productivity, maintenance costs, and asset utilization.
Ensure facilities comply with all applicable safety and environmental laws.
Provide field technicians with a mobile-friendly interface or mobile app.
By using a CMMS to help companies plan and manage assets and related maintenance expenses, companies can cost-effectively extend the useful life of assets.
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