Manufacturing Maintenance: 5 Quality Control & Efficiency Issues to Avoid Downtime

The journey to an efficient maintenance team across any industrial facility or manufacturing plant is dependent on a variety of factors, including an experienced, efficient maintenance staff.

However, without the proper tools in place to measure quality control and efficiency data and benchmarks, the maintenance team risks the possibility of downtime or an inefficient production schedule.

As a result, manufacturers witness breaks in production and are unable to fulfill the requests of customers, compromising quality and driving up maintenance costs.

The solution is a CMMS that is designed to manage all aspects of maintenance operations and prevent critical operational issues. To learn how to address quality control and efficiency issues with CMMS in your industrial or manufacturing facility, continue reading below.

 

  1. Commit to Implementation.

According to Software Advice, approximately 80 to 90% of all CMMS implementations fail. Why? CMMS failure can be attributed to poorly defined goals, lack of leadership buy-in, deficient training, a non-intuitive user experience, and more. The key to success? Commitment to implementation.

Armed with a powerful CMMS, manufacturers can successfully measure maintenance efforts to improve efficiencies and maximize return on investment. In order to do so effectively, gut check that your team is properly using the system with the following questions:

  • Are you proactively checking the system to monitor new or open work orders?
  • Are you updating your status in real time, so the maintenance manager knows when you have availability?
  • Are you following the preventive maintenance (PM) prompts to service assets before they breakdown?
  • Are you accurately logging overtime hours, so the maintenance manager understands what time is devoted to emergency work order requests?

By asking these questions, you’ll be able to create repeatable processes in your plant for continuous improvement.

 

>>>Related resource: What Does Successful CMMS Implementation Look Like?

 

  1. Require Training.

 To maintain quality control in your plant, it’s critical for your team to receive upfront training, whether on-site or remote. This will help your plant get up to speed on the software and its use cases. As far as CMMS training, the following topics are important to cover when defining processes:

  • System introduction and navigation.
  • Asset and PM management.
  • Work order management.
  • Inventory management.
  • Reporting

By training manufacturing personnel on these features, your team will follow a disciplined approach that produces consistent results.

 

>>>Related resource: To request further information about training, or to schedule a training session, click here to contact our training department.

 

  1. Improve Decision Making.

Managing a plant that has hundreds, if not thousands, of assets is a challenge. Without the proper tools in place, maintenance becomes more of a burden. And if not done successfully, manufacturing plants face serious risks, including downtime, product recalls and safety hazards. To ensure quality control isn’t easily lost in the shuffle of maintenance operations, it’s imperative that you gain visibility through asset management.

With asset management features on a CMMS, your team has access to unlimited amounts of manufacturer-related information. From specifications to metrics to PM schedules, management can make informed decisions about repairs and replacements. And with a better perspective of asset and operational performance, downtime will lessen. Not only does this improve the efficiency of your assets, but it also provides maintenance personnel with the information to ensure quality control.

 

  1. Maintain Inventory.

 A universal challenge for manufacturing plants is effective inventory management. With the proper tools in place, your manufacturing facility can achieve accurate and efficient inventory control. Instead of having to deal with the impossible task of managing spreadsheets, your team can easily manage available and reserved inventory items on a CMMS.

In doing so, equipment information is right at your fingertips to prevent stockout from occurring. This results in more effective control of parts and material inventories, and also improves speed and accuracy with repairs for more efficient service requests.

 

  1. Apply Preventive Maintenance.

Have you ever wondered just how much downtime costs your plant on a weekly, monthly or annual basis? According to a survey conducted by Information Technology Intelligence Consulting (ITIC), 98% of organizations say a single hour of downtime costs more than $100,000.

 Implementing PM schedules across your manufacturing equipment is the key to addressing quality control and efficiency issues. By placing an emphasis on PM schedules, your team is guaranteed to make better decisions and ensure equipment is functioning with the highest degree of efficiency.

And since all PM information resides in one place and can be associated with multiple assets, management has a clear picture into operations. This helps to keep your team and operations aligned by providing a single source of PM information for all stakeholders across the maintenance organization.

With the ability to monitor equipment and assets, comes greater responsibility for all personnel involved. As a result, management can address quality control and efficiency issues as needed.

For more information on how to address quality control and efficiency issues in your facility with CMMS, download our free ebook, A Manufacturer’s Guide to Preventive Maintenance with a CMMS.