One of the best practices for maintenance management innovation and technology is to adopt a proactive maintenance strategy, which aims to prevent failures and extend the life of assets, rather than reacting to them after they occur. A proactive maintenance strategy can include preventive maintenance, which is based on scheduled inspections and tasks, predictive maintenance, which is based on real-time data and condition monitoring, and reliability-centered maintenance, which is based on the criticality and failure modes of assets. A proactive maintenance strategy can help you reduce downtime, improve asset availability, lower maintenance costs, and enhance safety and compliance.
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The proposed proactive maintenance strategy is highly effective yet challenging to implement. It emphasizes preventing asset failures through preventive, predictive, and reliability-centered approaches. While its benefits include decreased downtime, improved asset availability, cost reduction, and enhanced safety, its success hinges on engaging not only the maintenance team but also other relevant departments. Achieving this cross-functional cooperation is key to maximizing the strategy's potential benefits.
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In my experience, here are three points that could help: Use technology to predict when equipment might have issues, allowing you to fix things before they break. Invest in sensors and data analysis tools. These help monitor equipment health, providing early warnings for potential problems. Make maintenance management more flexible and efficient by using mobile devices. This allows them to access information, update records, and communicate instantly. Integrate your maintenance software with your overall business systems, like an ERP. This ensures that everyone has the same information, reducing errors and improving coordination. The idea is to be in constant communication with real-time data and responses.
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Recording data collected via routine maintenance, condition monitoring and calibrations is essential to creating a proactive maintenance strategy. The database should be of a type that can be interrogated via standard queries and not one tied to a single vendor. Historical data and trends are invaluable.
Another best practice for maintenance management innovation and technology is to implement a computerized maintenance management system (CMMS), which is a software application that automates and streamlines the maintenance process. A CMMS can help you manage work orders, inventory, assets, schedules, budgets, reports, and more. A CMMS can also integrate with other systems, such as enterprise resource planning (ERP), Internet of Things (IoT), and artificial intelligence (AI), to provide more data and insights for decision making. A CMMS can help you increase productivity, efficiency, accuracy, and transparency in your maintenance operations.
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A CMMS, such as SAP, is regarded as a great tool for managing, controlling, and reporting on the performance of not just the maintenance program, but also the equipment. The cost of each piece of equipment and task is effectively calculated, manpower is precisely managed, and a tracing history is kept. Orders for spare parts and purchases are easily expedited. CMMS could explicitly manage asset integrity assurance inspections, characteristics, and pass/fail criteria.
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Based on my experience, I've found that even with the most advanced systems such as CMMS, ERP, and AIs, the human factor remains indispensable. As someone who has worked in this field, I understand that it's the human touch that ensures these systems receive accurate and comprehensive information. Moreover, a critical aspect is evaluating whether these systems align with your factory's unique requirements. Without this alignment, investing in them would be imprudent, potentially causing disruptions in information flow and unnecessary financial strain.
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Ramzi Aljilany
Senior Instrument and Control Technician at OMV | +33K Followers | +15.3M Impressions
A CMMS (Computerized Maintenance Management System) is a powerful tool that has the potential to revolutionize your maintenance management:- - It helps to organize, automate, and streamline maintenance activities, allowing you to make the most of your resources - It can save you time and money by helping to track assets, schedule preventative maintenance, report work orders, and ensure compliance. It can also help to improve the safety of your workplace and reduce the risk of equipment breakdowns - It help you to stay ahead of the curve and ensure that your maintenance operations remain efficient and cost-effective - It can also provide you with the data and analytics you need to make informed decisions about your maintenance strategy
A third best practice for maintenance management innovation and technology is to leverage emerging technologies, such as IoT, AI, augmented reality (AR), and drones, to enhance your maintenance capabilities and outcomes. IoT can help you connect your assets and sensors to collect and transmit data on their performance and condition. AI can help you analyze the data and generate predictions, recommendations, and alerts. AR can help you overlay digital information and instructions on the physical environment, to assist your maintenance technicians. Drones can help you inspect and monitor hard-to-reach or hazardous areas, such as roofs, pipelines, and power lines. These technologies can help you improve data quality, visibility, accuracy, and safety in your maintenance activities.
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In the realm of advancing maintenance management, integrating emerging technologies is compelling. This discourse on IoT, AI, AR, and drones highlights their potential in elevating maintenance. IoT links assets, AI analyzes data, AR guides technicians, and drones inspect challenging areas. However, experience cautions against hasty adoption. Many technologies lack testing, demanding comprehensive evaluation. Implementation and upkeep often exceed traditional maintenance. In my experience, opting for new machinery with integrated tech often outweighs retrofitting, considering complexities and returns. A balanced approach, valuing robust maintenance and cautious tech adoption, is key.
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Technology should simplify a) Allows process adherence b) Measurement of asset use c) Measurement of asset performance These three levers may be addressed by building domain knowledge Failure and repair data Spares and service capability QR code, Data , Analysis can provide first level win before we add more expensive sensors and trends. Cost effective solutions are effective operationally as well.
A fourth best practice for maintenance management innovation and technology is to foster a culture of innovation and learning in your organization, which encourages your employees to embrace change, experiment with new ideas, and share knowledge and feedback. A culture of innovation and learning can help you create a positive and supportive environment, where your employees are motivated, engaged, and empowered to improve their skills and performance. A culture of innovation and learning can also help you foster collaboration, communication, and trust among your teams, as well as with your customers and stakeholders. A culture of innovation and learning can help you drive continuous improvement, creativity, and value in your maintenance operations.
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Culture of any Maintenance or Preventive Maintenance department needs to have a consistent attention to detail For instance, if your company needs to be changing pump power ends every 15 months instead of 15 years, a Culture change may be needed.
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Ramzi Aljilany
Senior Instrument and Control Technician at OMV | +33K Followers | +15.3M Impressions
I think, It is important to utilize the latest technology and strategies to stay ahead of the competition and ensure your maintenance management procedures are up to date. By investing in innovative technology, you can create an efficient and productive working environment that encourages innovation and learning. This can help you stay competitive in the market and be better prepared for the future. Additionally, the use of modern technology and tools can reduce manual labor costs and simplify processes, resulting in improved efficiency. With the right maintenance management system, you can enjoy the benefits of increased productivity, improved customer service, and reduced operational costs.
A fifth best practice for maintenance management innovation and technology is to follow industry standards and best practices, which provide guidelines and benchmarks for your maintenance process and performance. Industry standards and best practices can help you ensure quality, consistency, and compliance in your maintenance activities, as well as align your goals and objectives with the expectations and requirements of your customers and stakeholders. Industry standards and best practices can also help you measure and compare your performance against your peers and competitors, and identify areas for improvement and innovation. Some examples of industry standards and best practices for maintenance management are ISO 55000 (asset management), ISO 31000 (risk management), ISO 9001 (quality management), and PAS 55 (optimal management of physical assets).
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Who do the best in class compare themselves to? How can you be sure you are comparing apples with apples and not oranges? How about you start by assessing where you are and where you feel your biggest gaps are - what is taking up the maintenance hours, dollars, resources - and then learning the best way to improve these in YOUR organization's operating context?
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All technologies and tools are efficient when it comes to maintenance but the main vital factor which can make them inefficient is the Human Behavior. The deviation backlogs, incomplete jobs, prioritization of non-critical equipment maintenance and all sorts of non-compliances impacting the works management thus creating loopholes for unnecessary equipment failures, delays to statutory equipment, bad equipment performances impacting production targets. If RCA's are conducted, the main equipment failure factor that tops all is the Human Behavior.
A sixth best practice for maintenance management innovation and technology is to keep up with the latest trends and developments in your field, which can help you stay ahead of the curve and gain a competitive edge. Keeping up with the latest trends and developments can help you discover new opportunities, challenges, and solutions for your maintenance operations, as well as learn from the best practices and experiences of other organizations. Keeping up with the latest trends and developments can also help you anticipate and respond to the changing needs and expectations of your customers and stakeholders, as well as the evolving regulatory and environmental conditions. Some examples of the latest trends and developments in maintenance management are digital twins, blockchain, 3D printing, and circular economy.
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Don't forget about the incorporation of social aspects; this has been one of the key trends in recent years. This approach encourages employee interaction and engagement within the system, blending technology and psychology to boost motivation and collaboration. For example, in our solution, every employee gets a personalized profile with tasks, device care, equipment logistics, and consumables management in their event feed. So, a manager 'liking' an employee's report provides instant motivation, creating a self-encouraging system that works well.
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With old equipment on an instable and unclear market, we are looking at replacing obsolete equipment with new equipment compatible and able to work on the old assets - this is one way we maintain the equipment running at relative low maintenance costs.
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Listen to you people. Learn about their skills. Many have more skills than just maintaining equipment some are leaders that sit back and watch the room and only speak when necessary. These. Are the people inwant in my corner. Encourage employees to speak up and air thier frustration and then as managers find a way to help and not sweep it under the rug .
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Assess your organizations readiness for change. Build a solid cultural foundation with the right leadership that is ready to champion industry best practices and new technologies. Without the proper foundation, culture, and change management, improvement/change initiatives will be short lived. Processes will revert to the old way of doing things because, âthat is how we have always done it.â Listen to the people that need to follow the business processes. If a process or the system is painful to work in, ask questions and work it out. The system provides the data the business analyzes makes decisions with, it needs to be high quality if you want to leverage it to make effective asset management/ maintenance management decisions.
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