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Key tools for industrial maintenance management

As technology advances and maintenance engineering develops, the numerous advantages of investing in asset management become more evident. This is because it is a strategic tool to optimize work and increase the company’s competitiveness and profitability.

Managers who insist on letting failures happen, choosing to deal with emergency corrections, put production at risk, and waste time and resources. To avoid losses and headaches, it is important that the industry sees maintenance as essential to the good production flow and ensures that it does not lack the most important tools for asset management.

Learn about the following key tools for the intelligent maintenance manager, who knows that there is no point in waiting for the defect to appear before fixing it when you can prevent it from happening in the first place. With these tools, your production will be optimized, your work will become more efficient, and your maintenance costs will drop dramatically. Enjoy your reading!

8 Essential Indicators for Maintenance Management

The most important tools for good asset management

Some several methodologies and softwares help the maintenance manager in controlling expenses, scheduling activities in an optimized (and even automated) way, and predicting failures in order to reduce unexpected production downtime. 

When implemented in the routine of equipment analysis and care, these techniques influence the company’s success, since they keep it updated in terms of market trends, make the environment safer for professionals, and increase profits, also improving its competitiveness.

By applying the tools listed below and measuring their efficiency through the indispensable management indicators, you can guarantee your organization will see the benefits mentioned above and the other advantages of working with strategic, assertive, and diversified asset management. Check out what are these techniques and how to add them to your maintenance plan:

TRACTIAN was named one of the fastest-growing SaaS companies in the world

Backlog

Intending to direct the teams’ work, the backlog is the sum of the hours of planned, scheduled, executed, and pending services, resulting from the activities of corrective, preventive, and predictive maintenance, including improvements. 

To make it simpler, it can also be understood as the labor time required to perform all services. This indicator includes all the activities that still need to be done — and not only those that are overdue — which makes it an excellent ally for asset managers, especially those who lead a large number of machines and professionals.

Reliability Centered Maintenance (RCM)

Developed by the US Army to extend the service time of equipment in a cheap and efficient way, RCM is a strategy that aims to optimize a company’s maintenance plan.

The methodology consists in selecting the activities required to maintain the availability and reliability of any production process and reducing the cost of asset maintenance as much as possible. Its results are so expressive that, over time, RCM has evolved to become one of the most efficient and cost-effective models for industrial equipment management.

Learn all you need to know about RCM (Reliability Centered Maintenance)

RCM steps

TPM: Total Productive Maintenance

Although the name Total Productive Maintenance is in English, the method was originated in Japan in the 1970s. The intention is to increase the production capacity of the equipment through the progressive modification of the maintenance techniques adopted. After all, every company that wants to improve its competitiveness must preserve the machines and the processes, keeping them under the ideal conditions of use. 

The TPM technique, therefore, is concerned both with corrections and with preventing failures, in addition to eliminating waste involved in the production processes.

What is Total Productive Maintenance (TPM)? Check it out here

5W2H

One of the simplest tools on the list, 5W2H (or action plan) is an effective and versatile method that can be used in several situations. Its main function is to simplify the plan and help the manager to organize maintenance activities in an assertive and intuitive way.

Through a checklist, this action plan allows quick visualization and comprehension of all steps and problems involved in the maintenance process. 

And the name 5W2H already explains how this methodology is applied in practice: the 7 letters involved in the acronym correspond to the fundamental questions for any asset or business management:

Check out our complete guide to Maintenance Planning and Control (MPC)

5w2h questions

FMECA 

A great way to analyze the criticality of equipment is by using Failure Modes and Effects Analysis (FMECA). Its purpose is to indicate how and why a given asset can fail, and how the consequences of such failure can be mitigated.

It also involves a criticality analysis that calculates the probability that the failure will not occur and its severity if it does. FMECA identifies the number of damages, occurrence, severity, and detectability of the failure, and also tracks the effectiveness of corrective maintenance. 

Consequently, the implementation of the technique improves production results, limits failures, and enables constant improvements through the analysis of past breakdowns.

Learn all about the matrix of criticality and how to classify your assets

PDCA cycle

An acronym for “Plan – Do – Check – Act”, the PDCA cycle (also known as Deming Cycle) is an iteration method — one that is repeated over and over again — used for the control and continuous improvement of production processes. 

This tool helps the manager to organize his ideas and projects, in the same way that it helps to split the work into several stages and tasks. Check out the PDCA step-by-step:

TRACTIAN is ranked as one of the 3 best maintenance softwares in the world

PCDA cicle

Online monitoring software

It is clear how technological tools have a positive impact on the various sectors of industry, including maintenance. By automating the processes through technology, the manager allows the team to invest efforts in tasks that matter, avoiding errors and eliminating waste of time and resources.

This automation, done by an online asset monitoring software, offers a better organization of the maintenance activities, the programming of service orders, the follow-up and analysis of the equipment and the useful life of each part, the calculation of the machinery productivity, among other fundamental advantages to improve the management. 

TRACTIAN is an example of a system for online monitoring, whose solution focuses on the data that really matters and that goes unnoticed by inspections performed by human efforts. The platform uses artificial intelligence to enhance maintenance management and ensure greater efficiency and profitability to the sector, reducing maintenance costs up to 60%.

Check out more about the TRACTIAN online monitoring platform here

The main tool is the good manager

The techniques and solutions presented above bring excellent results to assets and the maintenance sector, as long as they are led by a manager who thinks strategically and understands the importance of using technology and predictive maintenance to extend the useful life of equipment, improve its performance, optimize the team’s work, and avoid downtime.

How to achieve World Class Maintenance (WCM) in your industrial plant?

ebook downtime zero

One of the best strategies for the plan is to use online monitoring software on the machines, since they detect most of the information needed to evaluate the assets — when they don’t do the analysis and diagnostics themselves. As we have already said, in addition to anticipating failure and keeping machinery performance under the manager’s control, tools such as TRACTIAN’s automate the creation of service orders, allow more assertive scheduling of preventive inspections, facilitate decision making and activity planning, and increase the efficiency of machines and professionals.

TRACTIAN named in the Capterra Ranking for emerging favorite CMMS and OEE Software

To perform good asset management, the methodologies listed above are great allies, and easy to put into practice. But in order to make your management prevent more and spend less, controlling all assets in the most efficient way possible, the first step (and the smartest option) should be the adoption of a technology capable of monitoring and analyzing your machines in real time, without letting any information go unnoticed.

In this regard, you can count on TRACTIAN. Talk to one of our specialists or schedule a demo to learn more.

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About the author:

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Tamires Zinetti

Journalist, post graduate in Marketing and Digital Media with focus on Business, Law and Administration. She is a specialist in content production for industry and maintenance areas at TRACTIAN, responsible for helping teams in innovative processes.

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