Having an efficient and sustainable Maintenance, Repair and Operations (MRO) is a key contributor to achieving the financial and productivity goals of any organization. Ineffective MRO processes carry considerable risks on the integrated supply chain management model and can negatively impact on the internal business areas as well. Companies need to develop an ownership strategy when acquiring equipment to ensure they maintain performance at peak levels through its continued use. Optimizing the MRO processes is a sure fire way to increase visibility, extend plant mean times between failure, cut costs in maintenance and boost the overall equipment effectiveness. Here are some of the key practices for effective asset management.
Improve the Industrial Equipment Maintenance Design
Standard maintenance management practices are essential for the industrial plant to achieve high levels of productivity and reduce downtime. Use maintenance practices that are suited to meet your plant’s needs. Monitor all machinery regularly, check for all signs of wear and analyze trends in all the available data to detect potential failures and fix them before they occur. Though the implementation of a scheduled maintenance program is essential for your basic machinery needs, emerging technologies have made it possible to monitor performance and only provide support when needed. Installation of sensors in machinery allows for real-time monitoring by indicating the appropriate maintenance service to be addressed saving your company both money and time.
Train Maintenance Personnel on Equipment Technology and Usage
The long-term running of any automated equipment will require the personnel to have the necessary skills to handle it correctly. Operator training in heavy machinery should frequently be done as employees come and go and skills need to be touched-up now and then. Operator manuals can be revised and written in a simpler manner for easier reference. Embark on employee training and workforce development on ways to monitor and confirm that machinery, equipment and facility are well-maintained for efficient production.
A single dashboard can display quality information that helps the personnel to actively and remotely monitor the plant performance all-around-the-clock. This way, the user can track the equipment performance and address possible maintenance issues before they result in costly damage and unplanned downtime.
Vendor-managed Machinery Approaches
Many organizations have successfully partnered with OEMs that sold them the equipment to improve delivery performance, quality levels and help in complexity reduction. While on site, the OEM can inspect the equipment and introduce you to the available changes in the market. Additionally, the vendor could provide fully warranted replacement parts and 24/7 remote troubleshooting freeing up your personnel to focus on other tasks like operating the equipment and manufacturing products. They can provide valuable information and brief you on parts and components they plan on stopping to supply so that you can start looking for a possible replacement and budget accordingly.
Keeping a Critical Spare Part Inventory
Having a critical spare part inventory in a service-ready condition such that they are available and accessible when needed is quite important. The MRO storeroom inventory needs to be validated to ensure that the parts necessary for the operational equipment repair are held in stock and in good condition. If the organization is using old and obsolete parts, it’s time to shift the focus to getting lean efficiency parts that would result in significant improvement. An accurate Equipment Bill of Material (EBOM) should be maintained and measures should be put in place to ensure critical components are available from a reliable supplier as needed.
Measure and Continually Optimize the Process
A successful asset management strategy keeps evolving as the equipment, process and people change. Ensure to keep an updated list of critical plant assets and equipment changes. Before the purchase of equipment, make use of the components you already stock reducing the need to purchase additional inventory while keeping the technology variability on your floor at a minimum. Update and adjust inventory accordingly after the acquisition of equipment or major retrofit for continuous productivity gain.