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CMMS System: Integration for Off-site Operations
CMMS System: Integration for Off-site Operations
Paweł Bęś, Logistics and Maintenance Marketing Expert, QRmaint
Posted 6/11/2024
Computerized Maintenance Management Systems are often perceived as solutions that can operate solely in production plants. However, the growing demand for maintenance across production facilities has shown that the complexity of the business, and its need for integration is far more extended. Today, enterprises require CMMS integration with the supply chain—not only in the context of production, but also in the context of supplying manufacturing facilities with spare parts for their maintenance departments.
In this article, we explain how interoperability is facilitated today in maintenance operations. Using QRmaint as an example (a CMMS system that combines extensive capabilities of service and maintenance, asset management, and facility management) we will share knowledge about deep integration in manufacturing operations.
Image courtesy QRmaint
CMMS that Works Beyond the Production Plant
CMMS systems should completely cover multiple operations required not only for service and maintenance, but asset management and facility management systems as well.
Looking deeper into cross-connected areas in the production plant, we see that all internal departments are required to be informed about current events regarding ongoing operations. Whether the production line is dealing with unplanned downtime or scheduled maintenance, these events outline the need to get proper insights on task assignments and parts KPI metrics.
The people who need the data are maintenance managers, maintenance technicians, and machine operators. This is the first reason why deep integration between various departments has become increasingly important in manufacturing plants.
Areas that Require Integration
Production Line
Machine operators should be able to exchange constant data. The CMMS system offers the ANDON feature, an automatic calling system that allows for reporting issues and machinery failures on the production line.
Maintenance Workers
Technicians and maintenance staff can get data in real time about ongoing issues in the facility, whether it’s production line dysfunction or errors in the proper functioning of building infrastructure. By using the CMMS for maintenance, they can make material requests, like spare parts necessary to handle the situation.
Inventory Management
Warehouse clerks should keep the stock of spare parts low to maintain a cost-effective inventory approach. Therefore, they should exchange information with maintenance workers about required parts in real time. This also helps track the usage of spare parts and control the need for reordering.
Operational Management
Operations managers and team leaders responsible for the maintenance department can track ongoing tasks in an integrated CMMS system. They can assign work orders, see the progress of each task, and review KPIs at any time. This gives them a holistic view of all operations and where the teams are at the current time.
Finance Department
The finance department benefits from the CMMS by gaining insight into maintenance costs, including labor, spare parts, and downtime. This allows for more accurate budgeting and financial planning throughout the organization.
Supply Chain
The supply chain can seamlessly integrate with the CMMS to ensure timely procurement and delivery of spare parts and materials. This integration helps maintain optimal inventory levels, reduces lead times, and minimizes the risk of production delays. With CMMS, you can also choose your supplier and easily reorder exactly the same component, which is safe most of the time.
Putting it all together, there is one thing in common for all the areas here. Maintenance integration is about data exchange. By analyzing cost data, the finance team can identify savings areas and ensure efficient resource allocation. All of that leads to improved financial performance.
Real-time data exchange between the production plant and stakeholders in the supply chain ensures that maintenance activities run smoothly, which contributes to overall operational efficiency.
Considering these capabilities, we can outline what facilities maintenance is really like today. Data quality and data in place are two essential elements of today’s maintenance operations.
Hurdles of Integration in Manufacturing Plants
The way companies evolve over time indicates a more extended need for integration. There is no doubt that businesses have made many mistakes over the years, focusing on silos way too much. This caused them to create many separate legacy systems that need help to integrate. This is why integration between various departments becomes even more challenging to do.
An excellent example is the lack of mobile access within inventory management in the production facility. Production staff can’t effectively control goods flow by using paperwork, and the lack of mobile access often requires employees to check data on the PC workstation to see if it complies with paperwork and stock location.
Manufacturing company personnel encountered obvious issues with a lack of mobility, such as mismatches in production and problems with access to spare parts for machinery repair.
After a while, the company decided to deploy mobility in the production and for maintenance workers. They needed to integrate existing inventory management with new mobile solution.
Deploying a mobile app system for warehouse management wasn’t enough. Engineers needed to build and integrate a solution on top of the existing one with mobility, or completely replace the legacy system. Both cases were very time consuming and difficult to handle cost efficiently.
Main Hurdles to Operational Integration in Manufacturing Plants
Legacy Systems
As stated above, legacy systems are challenging to integrate, but businesses are still going along with them. Therefore, today, we have so many nonupgraded ERP systems with connected low-code platforms on top of and running maintenance operations with still relatively low agility. So, in many cases, it isn’t possible to integrate legacy systems, and these will need to be replaced.
Personnel
Computer operation was a problem in the past, but in the age of mobility and artificial intelligence, this is no longer a problem. Low-profile employees are very well educated in the use of basic mobile technology. The problem is convincing people to change. You can’t rely on a new integration solution with personnel who are not motivated. People lacking motivation will bring down even the most effective initiative.
Integration Cost
As mentioned above, if the integration solution involves deploying a new system that should integrate other systems, it may seem too costly. If it is too expensive, it will not be possible to proceed with it. Therefore, the CMMS integration operation should solve multiple problems and be cost effective.
Summary: CMMS Integration
It will be very difficult to run nonintegrated operations in a production plant today. Companies must adapt and improve data flow to tackle future and recent economic challenges.
Data is key today. It is a key to smooth operations, and it stimulates a more predictable work environment. Companies like QRmaint constantly take care of their data acquisition improvement. One example is the latest update they performed in their CMMS system.
The latest upgrade in the QRmaint CMMS system increased the ability to approximate input machine time. This upgrade was significant for running very accurate maintenance indicators such as MTTF or MTBF. Data taken on these indicators is a key to increasing maintenance efficiency.
In conclusion, improving your data exchange capabilities and CMMS integration can strengthen your production plant capabilities. You create a more agile and robust business by paying more attention to integration.
Paweł Bęś
Paweł Bęś, Logistics and Maintenance Marketing Expert for QRmaint. He is a B2B marketer with 8 years of experience in the logistics industry in the Netherlands. His work included business analysis of distribution and supply chain operations of high-tech companies in EMEA and APAC. He was responsible for directing, coordinating, planning and supervising transportation tasks and internal operations. He is currently responsible for marketing activities at QRmaint, a company that provides CMMS systems for various industries.
Many smaller companies feel maintenance management software is overkill for their organizations. Nothing could be further from the truth. In reality, even a one-person maintenance department can reap the benefits of maintenance management software. The same benefits realized by the maintenance crew in larger companies are there for smaller maintenance departments also.
Many smaller companies feel maintenance management software is overkill for their organizations. Nothing could be further from the truth. In reality, even a one-person maintenance department can reap the benefits of maintenance management software. The same benefits realized by the maintenance crew in larger companies are there for smaller maintenance departments also.
We now have the ability to automate many of our standard maintenance processes, analyse in detail various parts of our businesses, and the performance of our equipment. We are able to plan shutdowns, technical change projects and operational maintenance procedures down to a very fine level of detail. As maintenance management generally makes up around 40 - 50 % of operational budgets, the savings made possible from increased efficiency and reduction of waste are staggering.
We now have the ability to automate many of our standard maintenance processes, analyse in detail various parts of our businesses, and the performance of our equipment. We are able to plan shutdowns, technical change projects and operational maintenance procedures down to a very fine level of detail. As maintenance management generally makes up around 40 - 50 % of operational budgets, the savings made possible from increased efficiency and reduction of waste are staggering.
Facility management personnel in all industries have waited a long time for computer technology to become applicable and affordable enough to implement in their respective maintenance efforts. In recent years, flexible, dependable and economical computerized maintenance management systems (CMMS) have become available to help fight the never-ending struggle to operate and maintain buildings of all shapes, sizes and functions.
Facility management personnel in all industries have waited a long time for computer technology to become applicable and affordable enough to implement in their respective maintenance efforts. In recent years, flexible, dependable and economical computerized maintenance management systems (CMMS) have become available to help fight the never-ending struggle to operate and maintain buildings of all shapes, sizes and functions.
Training for users of a computerized maintenance management system (CMMS) is a multiple-phase process. There are three areas of training needs: basic training, application (CMMS) training, and internal training.
Training for users of a computerized maintenance management system (CMMS) is a multiple-phase process. There are three areas of training needs: basic training, application (CMMS) training, and internal training.
The effectiveness of maintenance can make the difference between success and insolvency, between limping by financially and organizational excellence. Many companies and organizations consider their computerized maintenance management system (CMMS) and processes as catalysts for achieving a competitive advantage. Yet, good intentions are only part of the recipe for success.
The effectiveness of maintenance can make the difference between success and insolvency, between limping by financially and organizational excellence. Many companies and organizations consider their computerized maintenance management system (CMMS) and processes as catalysts for achieving a competitive advantage. Yet, good intentions are only part of the recipe for success.
The degree to which RCM analysis can contribute to profitability is directly variable with the quality and accuracy of the CMMS data on which the analysis is based. Because the technique is rigorous, its over-use will defeat the purpose and lead to cost overruns instead of savings. The way to optimize the RCM return is to apply the analysis strictly to the equipment and systems that will pay off from it, and to know this we must rely on the CMMS. This paper provides guidance for ensuring that the equipment data and history residing in a CMMS are complete and accurate; so that RCM analysis will be a success and positively impact a company’s bottom line, not hurt it.
The degree to which RCM analysis can contribute to profitability is directly variable with the quality and accuracy of the CMMS data on which the analysis is based. Because the technique is rigorous, its over-use will defeat the purpose and lead to cost overruns instead of savings. The way to optimize the RCM return is to apply the analysis strictly to the equipment and systems that will pay off from it, and to know this we must rely on the CMMS. This paper provides guidance for ensuring that the equipment data and history residing in a CMMS are complete and accurate; so that RCM analysis will be a success and positively impact a company’s bottom line, not hurt it.
Maintenance management is an around-the-clock challenge. Equipment failure can (and does) happen at inconvenient times–times when maintenance managers may be off-site and must rely on communication from technicians to convey problems and act efficiently. Mobile computerized maintenance management systems (CMMS) and applications provide live, synchronized status reports and other key features that can dramatically improve reaction time and efficiency.
Maintenance management is an around-the-clock challenge. Equipment failure can (and does) happen at inconvenient times–times when maintenance managers may be off-site and must rely on communication from technicians to convey problems and act efficiently. Mobile computerized maintenance management systems (CMMS) and applications provide live, synchronized status reports and other key features that can dramatically improve reaction time and efficiency.
The latest ARC Advisory Group study of the enterprise asset management (EAM/CMMS) software market profiles more than 80 maintenance application suppliers. This number of choices is enough to make any plant manager shudder. How can you pick the tool that is right for you? The tug-of-war between decision makers can make or break the success of an EAM/CMMS implementation. This article addresses the delicate balance of wants and needs, and how they apply in the application selection process.
The latest ARC Advisory Group study of the enterprise asset management (EAM/CMMS) software market profiles more than 80 maintenance application suppliers. This number of choices is enough to make any plant manager shudder. How can you pick the tool that is right for you? The tug-of-war between decision makers can make or break the success of an EAM/CMMS implementation. This article addresses the delicate balance of wants and needs, and how they apply in the application selection process.
Now that the best EAM/ CMMS application for your business has been selected, the deployment phase begins. But an EAM system is not a plug-and-play application. Will you miss out on some real operational savings? Will the data be clean enough to provide value in a production environment? Will processes be tailored to match the new system, or will they be optimized to improve business? Is the vendor knowledgeable about your specific industry or regulatory requirements?
Now that the best EAM/ CMMS application for your business has been selected, the deployment phase begins. But an EAM system is not a plug-and-play application. Will you miss out on some real operational savings? Will the data be clean enough to provide value in a production environment? Will processes be tailored to match the new system, or will they be optimized to improve business? Is the vendor knowledgeable about your specific industry or regulatory requirements?
A whopping 94.7 percent of plant maintenance managers feel they are not using their computerized maintenance management software system to its maximum capability, according to the results of a national CMMS survey conducted for Reliable Plant magazine by educator, consultant and author Kris Bagadia. “I knew that it was going to be a high percentage. I didn’t know it was going to be that high,” says Bagadia.
A whopping 94.7 percent of plant maintenance managers feel they are not using their computerized maintenance management software system to its maximum capability, according to the results of a national CMMS survey conducted for Reliable Plant magazine by educator, consultant and author Kris Bagadia. “I knew that it was going to be a high percentage. I didn’t know it was going to be that high,” says Bagadia.
What is a failure code? Quite simply, it is a code that illustrates why an asset failed or the reason that the asset failed. Codes can be a number which is cross referenced to a list of actual code descriptions or more conveniently a series of alphanumeric characters that are a logical abbreviation of their descriptions. However, with modern database technology and available disk space, the full descriptions are increasingly being used instead of alphanumeric codes.
What is a failure code? Quite simply, it is a code that illustrates why an asset failed or the reason that the asset failed. Codes can be a number which is cross referenced to a list of actual code descriptions or more conveniently a series of alphanumeric characters that are a logical abbreviation of their descriptions. However, with modern database technology and available disk space, the full descriptions are increasingly being used instead of alphanumeric codes.
An elephant is a large animal and it is doubtful anyone would want to eat one. But the old proverb, with a little twist, has a similar paradox to implementing a computerized maintenance management system (CMMS). Not developing the proper steps to implementation may lead a company to failure.
An elephant is a large animal and it is doubtful anyone would want to eat one. But the old proverb, with a little twist, has a similar paradox to implementing a computerized maintenance management system (CMMS). Not developing the proper steps to implementation may lead a company to failure.
Most, if not all, companies use CMMS systems to oversee their maintenance activities. From home-grown systems to complete ERP systems, leveraging technology allows companies to more efficiently and effectively manage their maintenance, repair and operations activities. So as a core maintenance function, surely routine, lubrication-related preventive and predictive activities such as regreasing motor bearings, taking oil samples, and executing oil top-offs and inspections belong in the CMMS system like any other maintenance task, right?
Most, if not all, companies use CMMS systems to oversee their maintenance activities. From home-grown systems to complete ERP systems, leveraging technology allows companies to more efficiently and effectively manage their maintenance, repair and operations activities. So as a core maintenance function, surely routine, lubrication-related preventive and predictive activities such as regreasing motor bearings, taking oil samples, and executing oil top-offs and inspections belong in the CMMS system like any other maintenance task, right?
In this year literally billions of dollars will be spent, in many different countries, on implementing CMMS and enterprise level systems. Some corporations, such as RIO TINTO and BHP, have attempted to circumvent a lot of this cost by developing implementation templates for use across their global operations.
In this year literally billions of dollars will be spent, in many different countries, on implementing CMMS and enterprise level systems. Some corporations, such as RIO TINTO and BHP, have attempted to circumvent a lot of this cost by developing implementation templates for use across their global operations.
Defining the real need for new software and staying focused is tricky. There are so many variables along the way to a good software implementation that falling off the track is easy. There has to be a central theme to guide the decisions that will be made during the process. Simple steps early in the project keep decisions simple when times get tough.
Defining the real need for new software and staying focused is tricky. There are so many variables along the way to a good software implementation that falling off the track is easy. There has to be a central theme to guide the decisions that will be made during the process. Simple steps early in the project keep decisions simple when times get tough.
Good Computerized Maintenance Management Software (CMMS) that schedules preventive maintenance work orders on your equipment is an integral component of any efficient maintenance department. Preventive and scheduled maintenance, efficiently scheduled, will not only reduce your maintenance costs, but will minimize emergency repairs and downtime, resulting in an increase in overall profitability.
Good Computerized Maintenance Management Software (CMMS) that schedules preventive maintenance work orders on your equipment is an integral component of any efficient maintenance department. Preventive and scheduled maintenance, efficiently scheduled, will not only reduce your maintenance costs, but will minimize emergency repairs and downtime, resulting in an increase in overall profitability.
Industry pacesetters use real-time equipment data to prioritize and optimize their maintenance resources. The process is straightforward in concept: use real-time data to determine the equipment health, but only inform the Computerized Maintenance Management System (CMMS) when maintenance is actually necessary. From there, the CMMS automatically produces the work order and uses the workflow that is already familiar to all maintenance personnel.
Industry pacesetters use real-time equipment data to prioritize and optimize their maintenance resources. The process is straightforward in concept: use real-time data to determine the equipment health, but only inform the Computerized Maintenance Management System (CMMS) when maintenance is actually necessary. From there, the CMMS automatically produces the work order and uses the workflow that is already familiar to all maintenance personnel.
CMMS systems, as we have come to know them, come basically from two distinct families. These are ERP systems such as SAP, JDE and the PRONTO system and EAM systems such as Epac, MIMS and a plethora of other systems. When most maintenance practitioners refer to CMMS systems they are in reality talking about EAM systems.
CMMS systems, as we have come to know them, come basically from two distinct families. These are ERP systems such as SAP, JDE and the PRONTO system and EAM systems such as Epac, MIMS and a plethora of other systems. When most maintenance practitioners refer to CMMS systems they are in reality talking about EAM systems.
To manufacture products on such a large scale means stocking a lot of equipment to maintain the operation. Fort Saskatchewan plant in Alberta, Canada, Roy Lura, process leader, estimated an inventory of more than 15,000 pieces of equipment. Until recently, however, there was no way to adequately track the items. With the help of a barcode-driven tracking system, this has changed.
To manufacture products on such a large scale means stocking a lot of equipment to maintain the operation. Fort Saskatchewan plant in Alberta, Canada, Roy Lura, process leader, estimated an inventory of more than 15,000 pieces of equipment. Until recently, however, there was no way to adequately track the items. With the help of a barcode-driven tracking system, this has changed.
For most companies, gone are the days when users were forced to conform to a rigid framework dictated by the CMMS vendor and strictly controlled by the Information Systems department. Users today enjoy freedom to customise the content, look and feel of their CMMS environment on a variety of devices, from handhelds to desktops. With modern computers and software, users are overwhelmed with choices.
For most companies, gone are the days when users were forced to conform to a rigid framework dictated by the CMMS vendor and strictly controlled by the Information Systems department. Users today enjoy freedom to customise the content, look and feel of their CMMS environment on a variety of devices, from handhelds to desktops. With modern computers and software, users are overwhelmed with choices.
This paper presents an overview of an integrated process for system maintenance, fault diagnosis and support. The solution is based on Qualtech System, Inc.’s (QSI’s) TEAMS toolset for integrated diagnostics and involves several key innovations. As a showcase of the integrated solution, QSI, along with Antech Systems and Carnegie Mellon University (CMU), have recently completed a research project for the Information Technology Branch at the Naval Air Warfare Center–Aircraft Division (NAWC-AD) in St. Inigoes, MD. The entire system, termed ADAPTS (Adaptive Diagnostic And Personalized Technical Support), provides a comprehensive solution to integrated maintenance and training.
This paper presents an overview of an integrated process for system maintenance, fault diagnosis and support. The solution is based on Qualtech System, Inc.’s (QSI’s) TEAMS toolset for integrated diagnostics and involves several key innovations. As a showcase of the integrated solution, QSI, along with Antech Systems and Carnegie Mellon University (CMU), have recently completed a research project for the Information Technology Branch at the Naval Air Warfare Center–Aircraft Division (NAWC-AD) in St. Inigoes, MD. The entire system, termed ADAPTS (Adaptive Diagnostic And Personalized Technical Support), provides a comprehensive solution to integrated maintenance and training.
Much has been written in the past about the implementation of maintenance software (CMMS systems). This article takes a slightly different approach in that it attempts to explain some of the pitfalls associated with first time implementation in SME's. It suggests a "try before you buy" approach, which stages the maintenance software implementation to reduce both risk and cost. Tales of failed implementations abound and failure rates of 40% to 80% are commonly quoted. Real statistics are hard to come by but the following data is both relevant and current.
Much has been written in the past about the implementation of maintenance software (CMMS systems). This article takes a slightly different approach in that it attempts to explain some of the pitfalls associated with first time implementation in SME's. It suggests a "try before you buy" approach, which stages the maintenance software implementation to reduce both risk and cost. Tales of failed implementations abound and failure rates of 40% to 80% are commonly quoted. Real statistics are hard to come by but the following data is both relevant and current.
