Industrial Maintenance : challenges and best practices

Our advice and best practices for improving industrial maintenance management. Discover the different types of maintenance: corrective, preventive and predictive, and their impact on equipment performance.

The importance of caring about industrial maintenance

Industrial maintenance, which consists in continuously keeping a fleet of machines in working order, is nowadays a major concern. From productivity and safety to cost savings, manufacturers have every reason to take good care of their maintenance, and to consider implementing an effective industrial maintenance management strategy.

After all, maintenance management can really boost industrial performance. By relying on up-to-date technologies and, above all, careful supervision of operations, it is possible to achieve continuous, top-quality production. Discover the major role that CMMS software can play in reaching these goals.

 

What is Industrial Maintenance?

What is Industrial MaintenanceMaintenance can be defined as maintaining or restoring equipment to a state of operation that enables it to perform the service to which it is dedicated. This can include the replacement of minor parts (bulbs, cables, filters) as well as major operations and fine-tuning of machines.

And the importance of maintenance to industrial activity is constantly growing. In the industrial sector, it is often necessary to go beyond simple monitoring and aggregate a large amount of data to guarantee the operation of often complex machines. The accuracy of this data is essential to the performance of the organization, the quality of the end product, and the safety of all operators!

Nowadays, companies are looking to anticipation and automation to help them better define their industrial maintenance needs. However, conventional approaches are still widely used to meet urgent needs at lower cost.

There are three major types of maintenance:

  • Corrective maintenance: this is carried out as soon as a fault is detected, with the aim of quickly bringing the equipment back into working order. This may involve replacing or repairing a part or, in the case of curative maintenance, replacing all or part of the defective unit.
  • Preventive maintenance: this is carried out before any dysfunction occurs. Equipment is regularly monitored, based on specific criteria or at a predefined frequency. Thanks to increasingly rapid data collection in real time, preventive maintenance is constantly progressing, providing a high degree of agility.
  • Predictive maintenance: this type of maintenance exploits the full potential of data. Data collected on equipment is extrapolated to anticipate any faults or malfunctions. The company can then plan all necessary interventions at the right time, and minimize production downtime.

 

Why is Industrial Maintenance essential for your company?

Industrial maintenance is an essential part of an organization’s operations: it has major implications for the ongoing performance of equipment, and much more.

Costs and savings

Industrial maintenance and its management represent a major cost factor. Anticipating faults reduces the cost associated with emergency repairs, extends equipment lifespan, minimizes unplanned downtime and saves on energy costs.  These are all good reasons for companies to take control of their maintenance.

Industrial safety

Industrial safety, both for people and for the company’s physical assets, is at the core of maintenance operations. In the case of sometimes complex or dangerous industrial machinery, it is essential to keep equipment in good working condition, so that employees are not put at risk.

Productivity

Productivity

Effective maintenance management not only prevents costly and disruptive production downtime, it also helps to optimize the use of resources, better allocate working time and boost overall productivity. A fleet of equipment in good operating condition is the key to operational e fficiency: it guarantees high and stable production levels, while contributing to customer satisfaction through consistent delivery reliability.

Quality and image

The quality of end products depends on the quality of equipment. For any industry, it is therefore essential to ensure that the equipment is functional, in order to minimize the likelihood of product defects. Continuous production also has a positive impact on brand image, essential for standing out from the competition.

 

The lack of industrial maintenance can have a lasting impact on a company. Equipment deterioration increases the risk of many faults, and can result in production downtime. Significant costs are at stake, as well as the company’s reputation for reliability.

Some companies are implementing more global strategies to improve performance. Total Productive Maintenance or “TPM” is a system for optimizing production, safety and quality through equipment, processes and people.

 

How is technology shaping industrial maintenance?

How is technology shaping industrial maintenance New technologies are revolutionizing maintenance today: it’s now possible to go further in planning and anticipation, whatever the type of maintenance you initially chose.

Ever more sophisticated electronic sensors and the help of AI ensure real-time monitoring, as close as possible to each machine. This means you can monitor many different KPIs, and take into account the wear and tear and history of each machine to define ultra-customized maintenance plans.

In addition, software solutions such as Computerized Maintenance Management Systems (CMMS) offer complete visibility of machine fleets, spare parts inventories and technical intervention schedules. CMMS can address most industrial maintenance challenges by:

  • Reducing maintenance costs: an overview of costs, schedules and interventions enables you to optimize maintenance operations and group purchases;
  • Improving productivity: CMMS makes it possible to estimate repair times (MTTR) and the frequency of interventions (MTBF), thus reducing machine downtime as much as possible
  • Increasing equipment lifespan: equipment lifespan can be extended by 5 to 10%. Machine efficiency is improved over the long term thanks to better maintenance.

 

How to choose the right CMMS software?

There are several considerations when choosing a CMMS software package. Traditional solutions, which offer all the functions and dashboards needed to monitor a fleet, can be distinguished from enhanced solutions, based on cutting-edge technologies. The latter will bring greater mobility and collaboration to industrial maintenance. Often available as a SaaS solution, they can be easily accessed by all those involved in maintenance.

To select a software package that is truly adapted to your needs, you’ll also need to consider:

  • Features: whether comprehensive or limited, standard or sector-specific, they must be adapted to your particular activity.
  • User experience: the CMMS software you choose must be intuitive and easy for everyone to learn, if it is to be truly adopted in-house.
  • Adaptability: easy configuration, recent technologies and scalability of the tool are all important considerations for dealing with present and future needs.
  • Support and training: make sure your teams receive the support they need to get the most out of the tool.

Good CMMS software makes it easy to share data among all those involved, and provides accurate information on the condition of equipment at all times. With the right information at the right time, you can achieve your industrial maintenance objectives!

Be sure to take a close look at CMMS functionalities such as:

  • Equipment management
  • Service request management
  • Inventory and purchasing 
  • Planning 
  • Costs and budget 
  • Dashboards

Industrial Maintenance Industrial Maintenance Mob

Why does your company need a good Industrial Maintenance strategy and the right CMMS software?

From the human factor to purchasing parts at the right time, CMMS is the best way to keep control of your maintenance operations. New technologies are at the service of industrial maintenance, making it more precise than ever. To make the most of your CMMS solution, it’s essential to choose the right partner. This means deploying software that is tailored to your day-to-day needs, and capable of helping you meet all your time and productivity challenges.

Would you like to increase your company’s maintenance efficiency with CMMS?

Contact us to discuss your needs

Customer success

Who better to talk about it than our clients?

Dovechem, one of the leading chemical companies in the Asia-Pacific region.

Using the DIMO Maint CMMS tool made us change our procedures. For instance, purchasing used to be done entirely through paperwork. Now, the process is fully-digitalized and we have purchase order numbers, and POs are delivered by mail. Initially, whenever there was a need for a purchase order, we had to hand it over to the appropriate person in charge”.

Read the full testimonial from Dovechem

Elkem Silicones, world leader in silicones.

With DIMO Maint MX, we know the stock status. The solution is above all much more functional than Excel where you cannot do MRP or set alerts ».

     Read the full testimonial from Elkem Silicones

 

FAQ

What are the different types of industrial maintenance, and why are they important?

There are three main types of industrial maintenance: preventive, corrective and predictive. Preventive maintenance plans regular interventions to avoid faults, corrective maintenance repairs faults, and predictive maintenance uses technologies to predict problems before they occur. These types of maintenance maximize the efficiency and lifespan of industrial equipment.

 

What role do CMMS software play in industrial maintenance?

CMMS software can help you plan, track and manage maintenance tasks. They provide real-time data on equipment status, facilitating the early identification of potential problems. For example, CMMS software can detect an abnormal rise in machine temperature and alert the maintenance team.

 

How to choose the right CMMS software for your company?

The choice of CMMS software depends on your specific needs. You should consider several factors, such as the features available, ease of use, cost, compatibility with your existing equipment and customer support. For example, a heavy manufacturing company might prefer software with strong vibration analysis capabilities to anticipate failures.

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