Does your maintenance support increased productivity?
Is maintenance helping you meet production schedules?
Manufacturing maintenance teams are challenged with ensuring maximum availability of machinery and equipment to increase production capacity and efficiency. One of the key roles of maintenance is to keep production lines running without unplanned downtime; keeping machinery serviced, updated and running effectively to reduce the likelihood of breakdowns and stoppages.
Maintenance Management Checklist
Read the Maintenance Management checklist guide for top tips on how to optimise maintenance processes, meet production schedules and improve productivity.Learn more
Built on the MES TrakSYS™ platform from Parsec Corp, ITI Group’s (formerly Cimlogic) maintenance solution, including reactive maintenance, asset management and preventive maintenance modules helps manufacturers meet production schedules, reduce downtime, reduce repair costs and improve productivity:
- Enable accurate business planning based on true maintenance costs
- Understand accurate labour requirements to service your plant
- Understand the true cost of your machinery (is it costing more than it is worth?)
- Ability to plan maintenance according to live production schedules – single-view visualisation of production and maintenance data
- Enable smarter decision-making (auto-escalation of unanswered queries allows real-time intervention based on business priorities)
- Better visibility and management of maintenance activities, including resources, spare parts, equipment failure, breakdowns, their frequencies, and root causes
- Improved KPIs; Mean Time Between Failure (MTBF), Mean Time To Repair (MTTR), equipment downtime, Planned Maintenance Percentage (PMP), Schedule Compliance etc
What causes high maintenance costs?
- High maintenance costs can be experienced as a result of a number of things, such as; unplanned downtime, equipment faults, breakdowns and lost production from quality, time or speed. Even if equipment is operational, it may not be running at maximum speed, it may break down too regularly resulting in inconsistent product quality, excess waste, whilst disrupting planning and scheduling. Establishing the root causes of high maintenance costs is the first step to managing and reducing these costs.
- Unplanned maintenance results in lost production, higher part costs, and lost time for fixing the problem; costing significantly more than planned maintenance. Preventive maintenance can be planned, reducing the costs as shut down can be planned to coincide with production downtime. Therefore, preventive and reactive maintenance needs to be controlled and managed effectively to keep equipment producing consistently high product quality.
“Machines change quickly, as quickly as you can push a button, and people change over time. That said, we engaged our teams so that they knew what to expect, and now, well, TrakSYS has become so integral to what we do. We’d feel like we were operating in the dark if it was no longer available.”
Bernard Longmore, VP of Engineering, WaterWipes
View our Case Studies
WaterWipes Increased Capacity and Optimised Operations
Global Consumer Packaged Goods client achieves OEE efficiency gains and optimised control of production processes from real-time MES platform.
Cadbury’s New Chewing Gum Factory Development
ITI Group used simulation to help Cadbury overcome the typical challenges of planning and building a new factory; ensuring that the equipment selection, rules for operation, staffing levels and production capacity were all in sync with the business plan.
Marks & Spencer Distribution Centre: Simulation for Facility Design
ITI Group used simulation to help Marks and Spencer plc (M&S) design its 900,000sq ft distribution centre in Leicestershire.