Published On February 24, 2022 | 5 Min Read
The company wanted to increase its equipment uptime by implementing a proper maintenance management system to support the current production demand.
Due to the increasing demand for packaged foods, the company’s equipment needs to run more than 20 Hours Per Day continuously to support the demand. Hence, the equipment needs to be maintained timely and properly to avoid unplanned breakdowns. The maintenance activities were earlier logged on papers and maintenance works were carried out on a first-come, first-serve basis. There was no system in place to prioritize maintenance activities and track their progress real-time. Consequently, the equipment maintenance requirements cannot be tracked, which results in sudden breakdowns, causing production losses.
In order to handle the current situation, the company sought out a maintenance management system and conducted a lot of market research to find a system that would fit their needs. Following numerous research and demos, the company concludes that DreamzCMMS is the perfect fit for them. With the maintenance management system, they can keep track of all maintenance activities in one place with priorities, so that stakeholders can track the progress real-time. Additionally, the asset management and spare parts inventory management features help them manage their equipment and spare parts so that production can continue without any interruption.
There was a need to improve productivity and the production volume. This requires procurement of more equipment. It is cumbersome to keep records of all the equipment with pen and paper. Also, it is time-consuming to look through a mountain of papers in order to find the details of any equipment.
When DreamzCMMS is implemented, the equipment is digitized by filling out relevant information and onboarded into the system. All onboarded equipment is marked with QR Codes, making identification easier. Scanning the QR Code on the equipment enables a user to view details of the equipment like its value, depreciation, spare parts it is using and maintenance history . This simplifies maintenance by replacing the need to hunt through a stack of papers for relevant information during emergency situations.
In the paper-based system, maintenance activities are not prioritized or tracked real-time. In this situation, over and under maintenance of the equipment will result in failure of certain equipment due to under maintenance, affecting production during peak hours.
Using DreamzCMMS, equipment maintenance is easily managed. The maintenance managers can record a maintenance activity and then prioritize it to assign it to a technician accordingly. That way, the technician knows what equipment to go to first. While maintenance on an equipment, a technician go to the equipment’s location and scan the QR code on it. It helps him to get the equipment’s full details and maintenance history. So, the technician does not have to go through a pile of papers for the maintenance history. And it reduces his maintenance time. With the progress of the maintenance activity, stakeholders are directly notified on a real-time basis for each status update. So real-time visibility into the maintenance process and the reduction of maintenance time helped to increase the equipment uptime and production by nearly two-fold.
The increase in equipment necessitates a sufficient number of spare parts to maintain their smooth functioning. Earlier, spare parts details were captured in paper format, which lacked real-time stock visibility. In addition, due to human error, incorrect entries lead to the theft of spare parts. As a result, the company incurs heavy losses.
DreamzCMMS helped to organize the spare parts stocks in an effective manner. The technicians can locate the spare parts with their row, aisle and bin easily. And they can find them by scanning their QR Codes and consume. This helped them save a lot of maintenance time and increase equipment uptime. The management can now monitor the consumption of stocks and the procurements on a real-time basis. It is now easier to keep track of all spare parts. This reduced losses due to theft.
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