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Key tools for industrial maintenance management

22/10/2021• Reading time: 1 min• Updated 4 months ago

As technology advances and maintenance engineering develops, the numerous advantages of investing in asset management become more evident, since 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 not only production at risk, but also waste time and resources. To avoid losses and headaches, it is important that the industry sees maintenance as essential to good production flow and ensures that it does not lack the most important tools for asset management.

Types of maintenance: the complete guide

In this article, you will learn the key tools used by maintenance managers who know that preventing asset failure is the best way to optimize their results, instead of waiting for the machine to break down and then fixing it. With these tools, you will optimize your production, work efficiently, and drop your maintenance costs dramatically. Enjoy your reading!

8 Essential KPIs for Maintenance Management

The most important tools for good asset management

There are several methodologies and softwares that help maintenance managers to control expenses, schedule activities efficiently (and even automatically), and predict failures to reduce unexpected production downtime. 

When implemented in the maintenance routine, these techniques impact the company’s success, since they bring updates regarding market trends, make the environment safer for professionals, and increase profits, enhancing competitiveness.

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

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

Backlog

Aiming to guide the teams’ work, 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 professionals and machines.

Reliability-Centered Maintenance (RCM)

Developed by the US Army to extend the equipment uptime efficiently and with lower costs, RCM is a strategy that aims to optimize the company’s maintenance plan.

The methodology consists in identifying the main activities that will maintain the availability and reliability of any production process and reduce asset maintenance costs as much as possible. Its results are so expressive that, over time, RCM has evolved into one of the most efficient and profitable models for industrial maintenance management.

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

RCM Implementation steps

TPM: Total Productive Maintenance

Although the name Total Productive Maintenance is in English, the method was created in Japan in the 1970s. Its purpose is to increase the asset’s production capacity through continuous improvement and modification of the maintenance techniques adopted.

After all, every company that wants to increase competitiveness must preserve its machines and processes, by ensuring that they are kept under optimal conditions of use. 

The TPM technique, therefore, is focused on both correcting and preventing asset failures, as well as eliminating losses in the manufacturing process.

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

5 Whys & 2 Hows

One of the simplest tools on the list, 5W2H is an effective and versatile method that can be used in several situations. It helps the manager to organize maintenance activities and create an efficient action plan, by establishing the necessary tasks to achieve excellent results.

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

The name of the technique, 5 Whys and 2 Hows (5W2H), already explains how this methodology is applied: the 7 letters that form the acronym correspond to the questions that should be used for any asset or business management:

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

FMECA 

Failure Mode Effects and Criticality Analysis (FMECA) is an efficient way to analyze the criticality of equipment. This method indicates how and why a given asset can fail, and how the consequences of such failure can be mitigated.

In addition, it considers a criticality analysis that calculates the probability that the failure will not occur and its severity if it does. FMECA identifies the number of failures, frequency, severity, and failure detection, while also monitoring the effectiveness of corrective maintenance. 

Consequently, this technique implementation improves production results, avoiding failures and promoting continuous improvement through the analysis of previous machine downtime.

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 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

PDCA cycle

Online asset tracking software

It is clear that technological tools positively impact a variety of industry sectors, including maintenance. With process automation, the whole team can invest effort in tasks that really matter, avoiding errors and eliminating production losses.

This automation is done by online asset tracking softwares, which help managers better organize the maintenance activities, schedule work orders, monitor and analyze the asset and its lifetime, calculate production efficiency, among other key advantages to improve maintenance management. 

TRACTIAN is an example of an asset tracking system, which focuses on critical data that passes unnoticed by inspections performed by humans. The platform uses Artificial Intelligence to enhance maintenance management and ensure greater efficiency and profitability for the sector, reducing maintenance costs by up to 60%.

Check out more about the TRACTIAN online monitoring platform here

The main tool is a good manager

The techniques and solutions presented above bring excellent results to asset performance 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 asset lifetime, improve equipment performance, optimize the team’s work, and avoid downtime.

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

One of the best strategies for attaining zero downtime is to use an asset tracking software to monitor the machines, since it is able to detect most of the information needed to evaluate the equipment — and in some cases, it does the analysis and diagnostics by itself.

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 implement. But more than anticipating failures and helping you take control over your assets, tools such as TRACTIAN automate work orders, facilitate organization to schedule more assertive preventive inspections, help in decision-making and activity planning, and increase the efficiency of machines and professionals. 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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