The company desires to manage and perform the maintenance process on the equipment at a Manufacturing Company in a streamlined way to avoid unplanned failures and production losses.

Challenges 

The company’s manufacturing unit was spread across a large area. Observing and managing maintenance activities of equipment distributed across different locations was difficult. Maintenance of the equipment was performed based on the phone calls and e-mails received from the facility managers.  To register maintenance work orders and to track them formally was a challenge. This situation sometimes resulted in duplicate entries of work orders, resulting in time and effort being wasted due to repetition. The lack of scheduled maintenance leads to unplanned equipment failures. This caused costly reactive maintenance and downtimes.

Solutions

The management was seeking a software solution that will not only provide them with real-time visibility into the maintenance activities. But it will also provide them with easy and understandable data for future business decisions. The DreamzCMMS mobile solution allowed them to access data from anywhere, anytime. Through the request portal, facility managers and employees can now submit maintenance requests. The maintenance managers handle the requests and manage their progress for resolution through DreamzCMMS. It is now possible for management to monitor the work order status and review the maintenance process carried out by the technicians real-time. Reports are provided so that business decisions can be made based on a clear picture of the maintenance operations.

Effective Handling Of Work Requests To Work Orders:

The work requests are taken on the basis of phone calls and emails. This leads to human error in the form of duplications of requests or missing out on an important one, which may lead to downtimes and equipment failures.

The DreamzCMMS allows employees to log requests via request portal and monitor the status of those requests. It is now possible for employees to report incidents, problems and change requests. These requests are handled by maintenance managers. These maintenance requests can be converted into work orders, which are assigned to the technicians with the required skill sets. The status updates is visible real-time by the stakeholders. Hence it is increasing visibility in the operation.

As a result, management was able to review the maintenance process activities. And they can allocate skilled technicians based on their availability within the same work order to get faster resolutions. Thereby decreasing downtimes of the equipment and increasing productivity. Because DreamzCMMS is a centralized system, management can have all data pertaining to maintenance activities at their fingertips anytime. Furthermore, each work request and each work order are assigned different codes, allowing them to identify easily, thus reducing the chance of duplication.

Performing Scheduled Maintenance Activities With DreamzCMMS:

Due to the lack of a proper maintenance management system, it was nearly impossible to carry out preventive maintenance effectively. Lack of scheduled maintenance activities is causing sudden breakdowns resulting in costly reactive maintenance. Scheduled maintenance and checks include not just timely repairs of the equipment, but also do required meter checking.

The maintenance managers can now schedule maintenance activities on manufacturing equipment. It keeps its past maintenance history and other relevant details as reference with DreamzCMMS. Scheduled maintenance activities are created based on meter readings and time intervals and assigned to the technicians. Work orders for the scheduled maintenance activities generates automatically. And it notify the assigned technicians based on the set trigger conditions. Maintenance activities are carried out based on checklists provided in the Work Order for the technicians. This gives them clarity on what to do thus saving them a lot of time. As a result, scheduled preventive maintenance helped to maintain the equipment regularly, avoiding expensive reactive maintenance and downtimes caused by sudden failures.

Get Data For Future Business Decisions:

DreamzCMMS reporting feature gave management a detailed view of maintenance activities. They can now view details like maintenance history of the equipment, spare parts consumption during maintenance. Also they see the requests raised for the equipment and equipment failure details. This aided the company’s management in taking equipment repair / replacement and spare parts procurement decisions more efficiently. As a result it is saving a lot of money that added to the company’s profitability.