Sudden breakdowns of the company’s custom-built machines, resulted in loss-driven downtimes and costly reactive maintenance. To avoid unnecessary production losses due to sudden breakdown, they required a maintenance management solution.

Challenges

The company had a reactive maintenance program, which caused high maintenance costs and long downtimes, which led to heavy production losses. A maintenance request was taken via call and then assigned to a technician by the manager. Following the resolution of the issue, the technician conveys this to the manager via call. Therefore, the maintenance details of the machine are communicated via call and not stored. This also resulted in a major obstacle to financial audits due to the unavailability of historical maintenance data.

Solutions

Due to heavy losses from reactive maintenance and long downtimes, the company decided to adopt a maintenance management system to streamline its maintenance activities. Following extensive research, the procurement department of the company found DreamzCMMS to be a perfect fit. Using DreamzCMMS, the company has been able to perform scheduled maintenance and reduce sudden breakdowns and costly reactive maintenance. With DreamzCMMS, the team can now raise a request for a problem via a mobile app from anywhere. In addition, the company can now monitor spare part consumption and forecast which parts need to procure. With all the data, the company can easily carry out its financial audit, making better future decisions.

Streamlining Maintenance Activities

For its day-to-day operations, the company uses a variety of custom-built machines, including fillers, sealers, bundlers and stretch wrappers. Any machine failure can result in huge losses for the company. Previously, sudden breakdown of the machine was reported to the manager then he/she assigns a technician to the problem. The technician worked on the problem and resolved the same. Since, the entire process was on word of mouth, which made it impossible to track the maintenance activities. So the details of the maintenance are not recorded. Due to this, the technician has to investigate from scratch the problem that occurred earlier, resulting in prolonged downtime of the machine and severe losses of production.

Implementing DreamzCMMS enabled the company to log all maintenance-related requests and work orders and track them in real-time. Furthermore, it eliminated the need to call to report a problem to a large extent. Now, the machine operators raise a request about the problem for the machine tagged with them and the manager is then notified. The manager creates a work order, assigned to the technician, who carries it out, completes it and records it in the system. Technicians can refer to the details and maintenance history of the machine to investigate an error while on the job, resulting in less maintenance downtime. 

Reduction In Costly Reactive Maintenance By Adapting Scheduled Preventive Maintenance 

Through DreamzCMMS, the company is now able to implement preventive maintenance. Scheduled Maintenance or Preventive maintenance functionality is executed at specific intervals to avoid sudden failures and downtimes. Using historical maintenance data, scheduled maintenance for each machine was planned. Scheduled maintenance not only reduced expensive reactive maintenance due sudden breakdown but also provided better control of the workforce. Previously, a technician only engaged when a sudden failure occurred. Instead, they are now regularly engaged in scheduled maintenance inspections.

Get Alerts When Stock Of Spare Parts Are Lower

When a spare part was low on stock, it would be ordered based on an on-call request from the managers. This method involves manual work and can result in understocking and overstocking. DreamzCMMS allowed managers to set a reorder level, which determines how many stocks they should have for maintenance operations. If the level goes down, the managers are notified immediately for procurement. Furthermore, managers could see the actual quantity of stock while procuring it. This ensured that the company kept an optimal stock level for smooth maintenance operations.

Create Financial Audits Accurately

Currently DreamzCMMS is keeping all the necessary maintenance-related data and data related to stock consumption during maintenance and parts procurement made. So the financial audit for the company became more efficient. As a result, future strategic business decisions were more accurate based on data-driven analysis.