You’ve probably heard the saying, “the squeaky wheel gets the grease,” right? Well, machines have their own way of grabbing your attention — no squeaks necessary. If you look closely enough, factory equipment will actually give you clues about what’s going on so you can take care of problems before they even happen.
Now, let’s talk maintenance. Reactive maintenance is when you wait for things to break down and then scramble to fix them. This totally disrupts the workflow and can prevent your team from getting the job done. But here’s the thing — there’s a better way. Preventative maintenance is a proactive approach to taking care of machines. Instead of waiting for machines to break down, you can schedule routine maintenance tasks to keep everything running as planned.
Predictive maintenance takes this strategy a step further by using sensors and software to see into the future. By pairing your equipment with a computerized maintenance management system (CMMS), you can transform maintenance from reactive to proactive. Read on to learn how a CMMS helps keep machines running smoothly, which saves time, protects your investments, prevents accidents, and reduces stress for the team.
The Problem With Reactive Maintenance
Here’s another fitting cliche: If it ain’t broke, don’t fix it. But honestly, we’re not fans of that mindset. Reactive maintenance usually just leads to chaos when things go wrong. And let’s face it: unplanned downtime and emergency repairs are not only disruptive to production, but they’re also costly, and if they go unnoticed, broken machines are potentially dangerous.
On the other hand, proactive maintenance lets you address potential issues before they can become big problems. Say an engine’s running low on oil. That’s not a big problem on its own, but if you continue running the engine until it runs out of oil, it won’t take long before friction and heat destroy the engine. Some people keep track of maintenance tasks like topping off a machine’s lubricant by writing in a notebook. Others use simple spreadsheets. But if you add this information to a CMMS, the system can automatically schedule the time you would expect to need to add oil.
But it’s not just a matter of doing it on a certain timeline, like adding oil every 2 months. Instead, a good CMMS can set the schedule based on machine usage or historical data and automatically alert teams if anything breaks the usual pattern. This approach can help reduce unplanned downtime, keep machines in good working order, and streamline maintenance processes.
Why Real-Time Data Matters
As you add newer equipment with connectivity or retrofit existing equipment with sensors, you can take advantage of the Internet of Things (IoT). To make the most of IoT, integrate the information into the CMMS. One of the big advantages is that you’ll be able to make better decisions about maintenance schedules with accurate real-time data. Teams need up-to-date information to make quick, accurate decisions. Without real-time insights, issues can escalate before anyone notices.
Your CMMS can integrate with IoT sensors to provide a constant stream of data such as:
- Temperature of the machine or specific components
- Vibration
- Machine performance
- Environmental conditions
- Output
- Energy consumption
This data gives team leads and shop floor managers visibility into what’s happening across all equipment. It can also give you clues about what’s likely to happen in the future. In other words, it gives you the information you need to transform maintenance from reactive to proactive.
Extending Machine Lifespan with a Predictive Maintenance CMMS
Manufacturing equipment is expensive and it’s meant to last for many years. You probably don’t have the budget for replacing milling machines or industrial robots very frequently. Plus, even if you magically had unlimited funds, replacing equipment can be a major headache.
Predictive maintenance uses data trends to forecast when components will wear out. This allows teams to replace parts just before failure, avoiding both breakdowns and unnecessary early replacements. With a maintenance CMMS, you can schedule repairs based on your equipment’s actual condition, which is way more cost-effective. You’re only doing the work when it’s really needed, helping your machines stay in top shape longer and extending their lifespan. In the end, it maximizes your return on investment.
You probably already know that scheduling regular inspections and servicing machines helps machines work better and last longer. But let’s be real — scheduling all that can feel like a job on its own. Your CMMS can automatically send reminders for routine servicing. This helps take the stress off your team by preventing those surprise failures that can throw the whole shop floor off. Plus, it builds confidence that the equipment will perform reliably throughout shifts. Armed with maintenance data, you can optimize schedules to avoid downtime and increase productivity.
Other Benefits of Maintenance CMMS for the Shop Floor
Saves Time
We love a CMMS for maintenance, but that’s not the only benefit. It can save you tons of time because there are built-in features that automate administrative tasks. IBM explains that you can automate things like ordering parts, replenishing Maintenance, Repair, and Operations (MRO) inventory, scheduling shifts, and compiling information for audits. So, in an indirect way, you free up more time (and headspace) to focus on manufacturing.
Improves Workflow
Because it puts all relevant information into one central location, a CMMS also improves team coordination. There’s no need to cobble together information from different people and places. Instead, it’s all in one place, so everyone can see it and even interact with each other there. It’s easier to coordinate everyone’s efforts, even if they’re working different shifts or in different locations toward the same goal.
Maximizes Resources
A CMMS provides a unified view of everything. Software engineers and IT pros call it a “single pane of glass” because it pulls together data from multiple sources into one place. It’s like having a window into the shop floor, giving you a clear view of everything happening. But in this case, everything you see through that window is labeled and measured. Because you can access all relevant information without needing to switch between different applications or screens, you can improve resource allocation. This broad view of all the moving parts lets you figure out things like how to balance machine time with staff scheduling.
Enhances Safety
When equipment is maintained, it's going to operate the way you expect it to, with no surprise breakdowns or malfunctions. Keeping machines in excellent working order helps prevent accidents or injuries, ultimately, keeping teams safer.
Better Tools, Better Results
You wouldn’t give your team pocket knives when a die cutter precisely cuts large volumes. Tools matter, and software isn’t any different. A maintenance strategy for manufacturing is only as strong as the team and the tools behind it. The most eager and hard-working people can only accomplish so much if they don’t have the tools they need to get the job done. And these days, a CMMS is a crucial part of the toolkit. While this software can be a game-changer (for all the reasons we’ve talked about), there are a few potential pitfalls to keep in mind when you add new software into the mix:
- Consider integration by checking compatibility with existing systems.
- Prioritize data privacy and security.
- Keep in mind there will be a learning curve as teams get to know new systems.
With technology always advancing, even more advanced sensors and data analytics will likely play a bigger role in maintenance. By diving into a good CMMS now, you’ll not only tackle today’s challenges but also be ready for whatever comes next.
