September 2022 - 17

feature | reliability strategies
Left. The foundation of streamlined maintenance
is waste elimination, which can involve doing too
little or too much work.
Proactive maintenance is a broad term that
describes any maintenance strategy that aims
to service equipment before any signifi cant
deterioration. Preventive maintenance (PM)
is a commonly interchangeable term describing
a maintenance approach aiming to avert
equipment breakdowns. Many other categories
exist under these broad terms, with the
key variations having to do with the way they
trigger a maintenance requirement. Th e most
conventionally used PM strategies follow a
schedule- or usage-based approach.
Predictive maintenance (PdM) is one of
the more advanced strategies available today.
It capitalizes on gathering and analyzing
real-time data to detect the most subtle
indicators of suboptimal equipment
performance. PdM has provided real-life
maintenance cost reductions by 30%, while
improving unplanned downtime by 25%.
Whichever maintenance strategy you eventually
choose to trend your reliability the right
way, you will need an expansive view of your
assets. While this sounds like a daunting
task, the good news is that numerous tools
are available to make things easier and
more accurate.
For example, CMMS (Computerized
Maintenance Management Soſt ware) has
been around for decades. It's a tool that
incorporates the maintenance activities of
all assets within a facility. Typical automation
opportunities with a CMMS include
work-order generation, condition monitoring,
and execution progress.
EAM (Enterprise Asset Management)
soſt ware takes it a notch higher by looking
aſt er assets throughout their entire life cycles.
Modern EAM programs focus more on the
plant fl oor rather than just feeding data into
another system, such as an ERP. Th e capabilities
of modern EAM soſt ware broaden the
view to consider maintenance and performance
analytics and process improvements
to enhance asset effi ciencies.
Any available tool or application used to
streamline maintenance is only as good as
the data it receives. While CMMS and EAM
soſt ware have the brainpower to analyze
an entire operational facility, providing
incomplete or inaccurate data can throw
off what would have been a proper analysis.
Th ese types of soſt ware rely on accurate and
comprehensive material master data.
For instance, a Bill of Materials (BOM)
is a standard functionality of most modern
CMMS or EAM. An equipment BOM lists
all the bits and pieces of a component or
machine. While it can take time to perform
that initial step of building BOMs for assets,
the payoff is tremendous in terms of maintenance
effi ciency and automation. An accurate
BOM enables teams to identify a spare
instantly instead of siſt ing through drawings,
manuals, and endless catalogs.
Having accurate data in the system allows
teams to effi ciently execute planned work
schedules. Using CMMS or EAM to generate
work orders, for example, ensures that all
activities go through a documentation
system. Th is process allows maintenance
managers to track and refl ect the actual cost
of maintenance work. More importantly,
such a system paints a realistic picture of the
resources required for maintenance. Modern
apps make it easier for maintenance technicians
by providing mobile functionality and
user-friendly interfaces.
Effi ciency and improvements go beyond
the maintenance work and dive into the
activities that surround servicing equipment.
Th ink about streamlining maintenance as a
snowball eff ect that ensures benefi ts in stores,
inventory, and the supply chain.
A good example of expanding resource
effi ciency is using EAM to set up MRO
spare-parts stores to optimize inventory.
With an enterprise-wide view of maintenance
strategies and applicable assets, the
system can highlight opportunities and
eliminate redundancies.
A practical example is to keep track of
compatible spares with a pooled reserve
so that the facility will not need to hold as
many units. A data-driven analysis of spares
consumption is your best bet to assess which
parts to stock, quantities, and to determine
corresponding replenishment cycles.
Th e domino eff ect continues when the
time comes to issue an order. Modern EAM
platforms allow integration into procurement
systems that then automatically generate
purchase orders. Periodic reports, with access
to a thorough usage history, and dependable
forecasts give companies leverage when
negotiating with suppliers.
Reducing maintenance costs can easily be
misunderstood as simply slashing the budget
to achieve a target. However, streamlining
maintenance is actually about identifying
and eliminating the sources of waste and
maximizing available tools to fi nd better uses
for resources. A streamlined maintenance
approach paves the way for increased reliability
while achieving resource effi ciency. EP
Eric Whitley is Director of Smart Manufacturing
at L2L, Salt Lake City (,
where he helps clients learn and implement a
pragmatic and simple approach to corporate
digital transformation. In addition to many
publications and articles, he played a leading
role in the Total Productive Maintenance
eff ort at Autoliv ASP and in the Management
Certifi cation programs at Th e Ohio State
Univ., Columbus, where he served as an
adjunct faculty member.

September 2022

Table of Contents for the Digital Edition of September 2022

September 2022 - Cover1
September 2022 - Cover2
September 2022 - 1
September 2022 - 2
September 2022 - 3
September 2022 - 4
September 2022 - 5
September 2022 - 6
September 2022 - 7
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September 2022 - Cover3
September 2022 - Cover4