By: Lindsey Walker
Are you looking for ways to trim your ever-increasing maintenance management costs?
Are your maintenance expenditures wiping out all the profits you are striving to make?
Struggling to make the most of an ever-dwindling budget?
If these problems sound like your own, here is a simple 6-step strategy that you can use to reduce maintenance management expenses without compromising on production:
- Streamlining the Maintenance Schedules
As a maintenance manager, you should not be surprised if the senior management keeps a constant check on your department because maintenance management is a controllable department in any commercial facility to cut costs. However, as procedures continue to grow complicated over time, you may have to modify certain procedures. While it may need you to remove some redundant steps and add a few extra details, it is important to ensure that the job description does not get complicated and confusing. Several research studies have shown that the human mind faces difficulty when processing more than 7 things simultaneously. Identify the important steps and clearly specify them so that performing maintenance tasks becomes fast, easy and accurate.
- Ensuring that Your Technical and Non-Technical Staff is Adequately Trained
Major accidents and injuries mainly occur in the absence of education and this can cost your facility in more ways than one. Ensure that all your equipment operators and maintenance technicians receive proper training on safe work practices. Educating non-technical staff to identify unusual sounds and technical flaws will ensure that you prevent expensive and untimely repairs and replacements while extending the service life of your machinery.
- Creating Equipment Maintenance Calendars
Prepare a maintenance calendar for every month and every quarter with predetermined maintenance dates for critical equipment. Calendars will help in avoiding conflicts between predictive and preventive maintenance schedules and help you prioritize your budget for repairs and replacements. Try to leave some buffer time when preparing your calendar for unpredicted fire fighting and divide every week into different timeframes for tackling maintenance tasks that must be done on time and others that need to be done soon.
- Stay Prepared for Unplanned Downtimes and Unscheduled Outages
Avoid last minute troubleshooting, outages and disruptions by replacing your reactive “fix it when it breaks” approach with a proactive preventive maintenance strategy. Sudden breakdowns cost 10 more as compared to planned maintenance tasks. In order to prevent expensive failures and keep your vital equipment up and running you should ensure that:
- Replacement parts are always available
- PM tasks are well-documented
- Periodic inspections are scheduled for monitoring equipment condition
- Degrading performance is analyzed to identify the root cause
- Regular performance reviews are conducted
The upkeep of vital equipment is critical to operational efficiency and business success. Design a process that implements proactive practices whether your maintenance crew is dealing with unexpected system failures or working to prevent unplanned outages.
- Measuring Performance with KPIs
Key performance indicators that are generated from maintenance activities can be used for measuring both business performance and equipment performance. This valuable data can then be used for taking informed decisions related to training, creating accountability, improving practices, introducing troubleshooting checklists and making plant equipment choices.
- Take Advantage of Automation
There are various tools that can be used for improving operational efficiency, reducing downtimes, boosting productivity, improving workplace safety, maximizing equipment efficacy and minimizing unplanned outages. A computerized maintenance management system makes it possible to implement top-notch maintenance practices by enabling you to:
- Process work orders from any location
- Monitor all vital assets on any device
- Constantly track critical spare parts
- Generate precise reports
- Prepare accurate budget estimates
- Project maintenance requirements
- Determine resource allocations
- Share business-critical information interactively
The benefits of CMMS extend beyond the above-mentioned capabilities. It brings you the power to predict and improvise by offering a real-time view of what’s actually happening in real-time. This empowers you to shift your focus from fixing sudden failures to finding new ways to improve performance and reduce costs.
Lindsey Walker is the marketing manager for NEXGEN Asset Management. She excels at business development, project management and asset management. Her passion for writing allows her to share her knowledge on asset management, geographic information systems (GIS), software implementation, training curriculum development and similar topics.
Tags: Property Maintenance
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