The Strategic Role of CMMS For Manufacturing Businesses In 2024 & Beyond

Facility Management
Published on:
April 3, 2024
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In a manufacturing facility, a maintenance manager plays a vital role in ensuring uninterrupted operations, decreasing downtime, and getting the best performance from equipment.

Numerous manufacturing sectors are implementing Computerized Maintenance Management System Software (CMMS Software) to greatly augment their production processes. CMMS for Manufacturing offers a comprehensive solution to various industrial operations making it suitable at all times.

According to the latest data, sales of CMMS software are expected to reach $1.26 billion by 2026, growing steadily at an annual rate of 9.8% from 2020 to 2026.

And why might you ask?  The result is simply an astounding improvement in labor efficiency, a remarkable reduction in safety incidents, and a solid decrease in unplanned downtimes

The implementation of a CMMS app is simply an investment that is guaranteed to increase asset value and facility reliability. CMMS functionality is about providing strategies to make real-time or near-real-time business decisions. The effectiveness of any business decision is produced by the quality of information. Investments in various maintenance strategies, staffing efficiently, capital expenditure, and downtime planning all require the timely availability of accurate information to make a correct decision.

In this post, we'll explore the way CMMS software allows to revolutionize maintenance management in manufacturing, making your job easier and your plant more efficient. 

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What is CMMS for Manufacturing?

A computerized maintenance management system (CMMS) is software that collects and organizes maintenance info and allows maintenance operations processes.

It enables the availability and use of assets such as vehicles, equipment, communication, plant facilities, and assets to be enhanced.

Role of CMMS For Manufacturing

To be able to carry out maintenance procedures productively and effectively is crucial for industries engaging in manufacturing. CMMS functionality empowers manufacturers to decrease machinery breakdowns, proactively keep an eye on maintenance, and trim back downtime.

Moreover, it can perform functions like asset tracking, automating work orders, and even optimizing the overall efficiency of production, all of which can considerably improve the productivity and cost savings of manufacturer operations.

  1. Minimize Asset Breakdown

CMMS Software plays a critical role in decreasing asset breakdowns. By allowing preventative maintenance and timely repairance, CMMS authenticates that equipment and machinery are regularly inspected and serviced which will reduce the risk of unexpected breakdowns. Practicing this proactive approach businesses hamper the chances of copious downtimes, uphold their operational efficiency, and lengthen the duration of their invaluable assets that we consider as our Power Generation Equipment’s.

  1. Optimize Planning and Scheduling 

Automating the process of creating a maintenance schedule and assigning tasks to the right personnel is vital in any manufacturing industry. 

A CMMS for manufacturing streamlines this scheduling process and guarantees the timely execution of all maintenance tasks. By automating these tasks, CMMS improves efficiency, reduces human error, and optimizes resource allocation to improve overall maintenance management effectiveness and costs.

  1. Prevent equipment downtime

Facilities can be heavily affected by equipment failures and failures if not managed properly. A software system that automates equipment monitoring is a must to manage equipment losses or shortages. It can manage the equipment and machinery by giving important information such as usage running time, and compliance. The information gathered will provide a comprehensive view of purchase dates as well as any maintenance that has been done. CMMS functionality is vital to keep production maximized and on point. It will make sure the equipment is cared for and will prevent any future downtimes.

  1. Handle immediate machine maintenance requests

One must monitor machine performance in the manufacturing industry. Failure to appropriately monitor can be a disruption to the current production procedures. It is important that you accumulate data on all the assets within your industry. With an examination conducted on the maintenance history, you will be able to ascertain the machines that are failing, receiving an inadequate amount of attention, or not in superb condition as they need to be, thus allowing you to take the appropriate action.

  1. Documentation of Equipment Performance 

Industrial Maintenance Applications allow technicians to control work orders in actual time. Plant managers and personnel can monitor, prioritize, and monitor work requests to help ensure fruitful operations. Help requests with documentation can be submitted, work completed, and equipment healthiness surveyed.

Consequently, featured hardware overseers preserve data for evaluation, including job chronicles, user requirements, and legacy data for study and narration.

  1. Managing and knowing inventory

Preventing unnecessary purchasing is often underestimated but paramount is possible with cloud-based CMMS for manufacturing.

Solely maintaining your asset will not usually transform and bring enormous improvements to manufacturing but it is paramount. Shortages, overstocking problems, and missing spare parts will cause substantial disruptions in production and rescheduling of deliveries.

A world of efficiency with CMMS functionality provides optimal inventory management and streamlining procurement that enables you to have the right item when you need it.

  1. Reduced Asset Downtime

98% of firms report that a single hour of downtime costs them more than $100,000. CMMS software is a major factor in reducing asset downtime.

By effectively scheduling and managing maintenance tasks, CMMS for manufacturing guarantees that equipment is properly maintained and less susceptible to unplanned breakdowns. Consequently, operations run smoothly, avoiding downtime and enhancing overall productivity and asset reliability.

Mobile Integration with CMMS Apps

For a long time, manufacturing has recognized the role of Computerized Maintenance Management Systems (CMMSs) in inefficient maintenance management. Now, with the advent of CMMS mobile apps, the CMMS functionality is transformed.

CMMS apps take the feature set of a CMMS and provide it at a distance, in real-time. In this analysis, we’ll look at the specific benefits of CMMS apps and how they bring extra capabilities into traditional CMMS services for manufacturing.

Benefits of the CMMS App Integration

Availability on Mobile

Typical CMMS for manufacturing solutions often limits technicians to stationary desktop computers, keeping them from working while on the go. Conversely, CMMS apps eliminate this inconvenience, providing technicians access via smartphones and tablets. 

Mechanics can find vital information, alter work orders, and complete tasks anywhere on-site, dramatically enhancing response time, and decreasing downtime.

Real-Time Update

CMMS applications bring real-time updates for maintenance activities. Tasks will be instantly logged on the CMMS app when they are done by the technicians on the field. Issues with the equipment(s) will be submitted and problems will be resolved faster. Inventory quantity will be automatically updated because the CMMS app will digitally record the items' usage. With real-time data, maintenance managers will acquire every minute of information. Maintenance decisions will be made quicker and more overall equipment effectiveness (OEE) will be achieved.

Better Collaboration

Mobile CMMS applications promote team collaboration among maintenance personnel. Through the app's messaging and commenting functionality, technicians can notify each other, trade concepts, and work together on complex issues.

Now that members of the team can coordinate their efforts and provide their skills immediately – regardless of where they find themselves – the outcome is a work environment in which cooperation is not only achievable but a necessity.

Increase Precision and Effectiveness

Mobile devices restrict the probability of bodily errors correlated with entering data. Technicians can easily feed details straight into the CMMS app by using mobile devices, restricting the risk of errors transcribed mistakenly.

Additionally, real-time data feeds streamline the process. Organizations can lessen formalities and guarantee data is instantly ready to be shown to significant shareholders.

CMMS Best Practices

1. Implementation 

To implement CMMS for manufacturing, a systematic approach must be used. Begin by evaluating the maintenance needs and goals of your organization. CMMS functionality Goals should be clear and concise, whether it’s reducing downtime, extending the life of assets, increasing overall efficiency, or something else of importance. By bringing together key stakeholders from maintenance, IT, and management, a diverse range of perspectives will be embraced. Create a schedule that illustrates the highest priorities. Ensure that the selected CMMS is customizable to the organization.

2. User-Training 

  • Training of users is of utmost importance for the successful implementation of CMMS in an organization. Conduct all-inclusive training sessions for various stakeholders – maintenance technicians, administrators, and all users who will be using the system.
  •  Frame different training programs for different roles such as requesters, approvers, and technicians. 
  • All training courses must focus on practical aspects like work order creation, preventive maintenance scheduling, and data entry. 
  • Update all your training materials with the addition of new features and system upgrades. 
  • Create a feedback loop to address user concerns and continuously improve the training process.

3. Data-Management 

To effectively utilize the CMMS for manufacturing processes, data management is crucial. 66% of maintenance professionals across industries said they use CMMS to track their maintenance programs, a 24% increase from 2019.

A database audit and cleaning process should be performed at regular intervals to remove outdated data and eliminate redundancy. Error prevention can also be achieved by instituting data validation routines. Integrate CMMS with other relevant systems such as asset management, and Enterprise Resource Planning tools to increase data accuracy and streamline processes. To avert loss and facilitate disaster recovery, regularly backup data.

4. Achieving High Adoption Rate 

For utilizing full CMMS functionality, it must be widely adopted by users.

To drive up adoption rates, create an accountability culture, stressing how CMMS will positively affect individual and group performance.

Routinely solicit user feedback to ascertain where the software is falling short and promptly attend to identified pain points. Reward spirit as well as results by recognizing employees who actively use the system; then, publicize their successes to excite others. Finally, provide ongoing support, whether through a help desk staffed with experts or a knowledge base full of daily answers.

5. Optimizing System Usage 

To optimize CMMS for the manufacturing industry, refine the processes using the system, and adopt new tools.

Regularly review the system feedback and performance to expose areas for further improvement.

Stay current with software releases and install updates as soon as they become released for added features, bug fixes, and security patches.

Explore useful features, such as predictive maintenance or mobile companions. Review the system performance periodically to look for opportunities to further improve usage.

Understanding CMMS Pricing Models

To find an effective maintenance management solution, businesses should know the details of CMMS pricing models, including subscription fees and one-time licensing fees.

With subscription-based pricing, you are charged after a certain level of free usage, typically per API request or data transfer. Free entry-level usage is offered, and beyond that payment is based on tiers, with the price decreasing per unit as quantity increases. However, some providers also offer pay-as-you-go in addition to free entry-level usage.

Alternatively, some CMMS providers charge a one-time license fee, in which businesses pay a single up-front fee for perpetual rights to use the software.

This version of the service may involve other fees, such as an initial implementation cost or ongoing maintenance charges. Although the initial financial investment is significant, this model of CMMS can be more cost-effective in the long run for firms with projections of extended usage. However, it isn’t an ideal solution for organizations requiring basic features.

It is essential to perform an ROI analysis while evaluating CMMS pricing. Enterprises must evaluate the expected returns, like longer asset life, reduced downtime, better maintenance efficiency, etc. A properly implemented CMMS can help organizations save a ton of costs. It prevents unexpected downtime, optimizes maintenance schedules, enhances equipment's overall effectiveness, etc. If we calculate the ROI, we need to consider all the benefits against comprehensive costs, and these costs include software license costs, implementation costs, and ongoing support costs.

Key Factors Impacting CMMS Software Spending

The CMMS pricing can be influenced by a variety of issues, which is why organizations need to take a judicious approach to evaluate their specific needs:

  • Larger firms with more assets can encounter higher expenses owing to increased installation and user numbers.
  • The complexity of the CMMS functionality – that is, the level of integration with current systems as well as any customizations – will affect costs. 
  • Customizations to reflect certain workflows or meet certain industry regulations may also come with additional expenses.
  • The cost of a CMMS often increases as the number of user licenses goes up. Additional costs may result from the need to offer access to multiple locations or support different user roles.
  • With cloud-based CMMS software, you may have to pay subscription fees for hosting and maintenance. Instead, with on-premises deployments, you will encounter higher upfront costs for hardware and infrastructure but lower ongoing fees.
  •  CMMS platforms often offer add-on modules or advanced features that can increase functionality. While these extras may come with a price tag, they can be essential for organizations with specific needs.

Analyzing CMMS Reports

The right type of CMMS reports can give you a big-picture view of your maintenance operations, the condition of your assets and equipment, and the effectiveness of your maintenance procedures.

In this context, understanding CMMS report examples and knowing what to look for can help you make data-driven and informed decisions to improve your manufacturing process.

CMMS Reports Example 

  1. Work-Order History Report

This report tells you everything that’s happened with your work orders, listing completed, open, and overdue tasks. It’s like a snapshot of all of your maintenance activity and points out areas where you’re doing well, and spots where you might be having problems.

What do you do with this information? If work orders are one of your goals, you should be focused on keeping completed work orders high and backlog and overdue work orders low.

  1. Equipment Downtime Report

 This report measures the duration and frequency of equipment downtime, providing insight into the reliability of your assets.

What do you do with this information? downtime patterns help you recognize which equipment is critical, which issues recur regularly, and where maintenance can be scheduled. Less downtime indicates improved asset health and operational availability.

  1. Preventive Maintenance Report 

This report assesses the following of scheduled preventative maintenance highlighting the effectivity of maintenance plans. 

What do you do with this information?  High rates of compliance indicate an approach to maintenance that is proactive and much less unexpected breakdowns. Low compliance usually signifies a need to improve scheduling or communicate effectively.

  1. Inventory Management Report

The insights provided by this report contain information regarding the usage of spare parts, the levels they are kept at, and their re-order points.

Interpretation: The maintenance of the inventory at optimum levels ensures timely furnishing of parts and minimal equipment downtime. Analyzing trends in the usage of parts helps make strategic buying decisions and thus avoid unnecessary hoarding.

  1. Asset Performance Report

This report examines the performance of assets holistically when considering elements such as Mean Time Between Failures (MTBF) and Mean Time to Repair (MTTR).

Interpretation: An increase in MTBF suggests that the equipment reliability has improved. Conversely, a decrease in MTTR indicates that the response time for maintenance is more efficient.

Wrapping it Up

As companies look to streamline processes and focus on the bottom line, computerized maintenance management systems (CMMS) are emerging as a key strategy for improving operational efficiency. The implementation of CMMS  for manufacturing offers preventive maintenance, asset tracking, and real-time monitoring, all of which help reduce downtime and extend the life of critical equipment. 

Through the use of CMMS reports, manufacturers are provided with a complete view of work order history, equipment downtime, and overall asset performance — giving them the data they need to make smarter, more informed decisions.

Created to merge seamlessly manufacturing business operations, maintenance management, and safety compliance, Xenia unifies facility management processes for peak facility performance. With an easy-to-use interface accessible from both desktop and mobile devices, Xenia allows users to schedule and conduct manufacturing plant inspections with ease.

Why Xenia?

  • Streamlines the creation of standardized processes, ensuring uniformity and compliance with regulatory requirements.
  • Increases inspection efficiency by decreasing manual intervention and guaranteeing complete evaluations.
  • Increase productivity with clear work schedules and real-time mobile device notifications.
  • Remove shortcuts to ensure accountability; require photographs, notes, and templates for detailed work documentation.
  • Centralize request management, accelerate approvals, and keep track of associated expenditures and resources to ensure an effective process.
  • Encourage successful cooperation by using fast chats, group updates, corporate announcements, and task mentions.
  • Improve issue management with mobile reporting, remedial measures, and live progress monitoring.
  • Improve decision-making by utilizing precise work analytics, powerful filters, and customizable data exports.
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