In today’s ever-evolving manufacturing landscape, technology plays an increasingly critical role in driving operational efficiency and competitiveness. It is challenging to keep up with a growing arsenal of technology solutions and ensure they integrate seamlessly with one another. But if done well, integrated tech can drive compounding efficiencies. One area ripe for transformation is maintenance, an indispensable function for ensuring equipment and production reliability.
In a recent edition of the Advanced Manufacturing Now podcast, host Lawrence Moebs explored the transformative power of integrated maintenance management software with Bryan Christiansen, CEO and Founder of Limble CMMS. The discussion was full of insights and observations gleaned from years of serving industry professionals.
Key Benefits of Maintenance Management Software
Many organizations view maintenance as merely a cost of doing business. Christiansen’s primary piece of advice for manufacturing organizations hoping to improve efficiency and production is to commit to a paradigm shift. Maintenance departments that strategically apply modern maintenance practices bolstered by technology have the potential to drive profits and growth. For manufacturers, the question becomes not “How can we afford to invest in maintenance?” but rather, “How can we afford not to?”
“Companies are now realizing that they can not only save but actually make a lot of money if they run maintenance the right way because everything just works better,” shared Christiansen.
Aside from simply adding more organization to a maintenance team’s work, Christiansen shared some of the underlying benefits he has seen throughout his experience of helping maintenance professionals make the most of their technology solutions. The outcomes are far-reaching, and impact numerous areas of the business.
Downtime Mitigation
Downtime is the ultimate enemy of manufacturing productivity. Every hour of lost production translates to financial losses. Maintenance software like a CMMS (Computerized Maintenance Management System), ensures critical tasks are completed to prevent downtime. Christiansen shared that many teams have been able to deliver accelerated response times during an unexpected breakdown as a result of having a centralized system where important asset details, work aids, and parts information can be accessed.
He further explained that reducing downtime often comes down to three key functions that a CMMS can facilitate.
- Asset Inventory: Knowing what equipment is in operation and making important information and histories on those assets easily available.
- Preventative Maintenance Scheduling: Automatically alerting maintenance teams to perform essential tasks like greasing machinery or replacing worn-out parts.
- Spare Part Management: Ensures necessary parts are available when needed, reducing delays.
These capabilities collectively save companies millions by maximizing equipment uptime and operational output.
Labor Efficiency
Technicians thrive when equipped with the right tools. Maintenance software eliminates inefficiencies like searching for manuals or troubleshooting charts, or seeking support from colleagues. With access to all necessary information on mobile devices, technicians can focus on what they do best—fixing issues.
According to Christensen, customers often see up to a 41% improvement in labor efficiency. This has become a critical win as more and more customers report a dwindling pool of maintenance professionals in their hiring pipeline.
Reduced Spare Parts Spending
Mismanagement of spare parts has the potential to significantly increase costs. Maintenance management software optimizes inventory, ensuring companies stock just enough parts without overspending. Numerous examples of customers saving thousands of dollars every month have been an early win for many organizations moving toward a maintenance management system.
Christiansen explains that this is such a significant need in the industry that Limble has been investing in the development of additional parts procurement products and tools for their customers. Upcoming enhancements aim to provide price comparisons across vendors, delivering even more savings.
The Power of Technology Integration
According to Christiansen, integration is the secret sauce that makes maintenance management systems so impactful. Siloed systems and disparate tools used across and even within departments hinder visibility and collaboration. Here is a breakdown of the three types of technologies Christiansen highlights that when integrated with each other to support maintenance activity, can become a “greater than the sum of its parts” scenario.
IoT Sensors
The Internet of Things (IoT) enables predictive maintenance by feeding real-time asset data—such as temperature and vibration metrics—into maintenance or asset management software. This data can then be analyzed to trigger alerts regarding potential failure or necessary maintenance, helping teams avoid issues before they occur. IoT is especially useful for critical equipment and reducing safety and compliance risks.
ERP Systems
Enterprise Resource Planning (ERP) systems are the financial backbone of manufacturing organizations. Integrating maintenance software with ERP platforms like SAP or NetSuite ensures seamless tracking of expenses, spare parts procurement, and asset history. Finance teams gain a transparent view of operations, empowering smarter budgeting and investment decisions.
Production Systems
Systems like SCADA and historian platforms can be linked to maintenance software. For instance, when a fault is detected in production, a work order can be automatically generated, ensuring quick detection and resolution. This synergy between production and maintenance departments improves performance and lowers costs.
Breaking Down Barriers to Adoption
Despite the benefits, maintenance teams often have a hard time gaining support for investments in technology and other resources. Christiansen explains that those obstacles exist for good – but increasingly obsolete – reasons.
First among them is outdated perceptions of CMMS solutions. Older CMMS platforms were indeed clunky to use, time-consuming to implement, and labor-intensive to maintain, which sometimes created well-earned skepticism about their effectiveness. Modern solutions like Limble, however, are an entirely different animal. They are user-friendly, cloud-based, and quick to deploy, delivering ROI in as little as three weeks.
Second, budget constraints also made the investment hard to make. With maintenance historically viewed as a cost center, it was difficult for teams to secure funding for systems that were seen as lacking in effectiveness (as discussed above).
Today, CMMS systems can deliver savings and efficiencies faster and to a higher degree than ever before at a fraction of the cost in terms of implementation time and licenses. In addition, they have helped organizations recognize maintenance as a profit-driving function, facilitating easier buy-in from leadership.
What’s Next for Maintenance Software?
Christiansen sees a bright and exciting future for maintenance management software and the professionals who use them. He believes the key to future growth lies in further innovation and integration. Limble is already developing new products and features to address common challenges, such as spare parts procurement. By giving customers tools for comparing prices across vendors, customers can significantly on parts.
Moreover, as technologies like AI and machine learning advance, maintenance software will become even more predictive and prescriptive. Integration with emerging tools will unlock smarter insights, helping manufacturers achieve unprecedented levels of efficiency.
Getting Started with Maintenance Software
For manufacturers still relying on pen-and-paper systems or outdated CMMS platforms, the journey to modernization can feel daunting. Christiansen advises starting simple: adopt a CMMS and focus on building a robust preventative maintenance strategy one asset at a time. Once foundational practices are in place, organizations can explore deeper integrations and advanced features.
To learn more, check out limblecmms.com where you can explore hundreds of blog posts on topics like these and other best practices, or peruse our case studies for inspiration and insights. Finally, the Limble Community is a great resource for maintenance professionals looking to share tips and support each other in their work.
Final thoughts on building a culture of maintenance excellence
Ultimately, the shift toward proactive maintenance requires more than technology—it demands a cultural change. Maintenance teams must be seen as strategic partners, not just cost centers. By investing in modern tools and fostering collaboration across departments, manufacturers can unlock the full potential of their operations.
