Keeping up with maintenance in a manufacturing facility can be daunting, particularly if you don’t have automated or digital operations. That’s where a CMMS comes in. You may know that a CMMS can help organize maintenance work, but the ripple effects of a well-utilized modern CMMS can mean so much more, from reduced downtime to improved team morale and employee safety.
In this article, we’ll cover what a CMMS does, how it can benefit businesses in the manufacturing sector, and the top features to look for when considering a CMMS for your manufacturing company.
What is a CMMS?
A Computerized Maintenance Management System (CMMS) is a cloud-based software platform designed to help manage and streamline maintenance processes. It helps maintenance teams and leaders automate maintenance workflows and schedules and leverage team and equipment performance data, generating detailed analyses for more informed and strategic decision-making.
CMMS platforms allow maintenance teams across various industries to better track their maintenance activities and assist in deploying and managing preventive maintenance programs. Because most of them have a mobile maintenance application and remote mobile device access, staff can easily access the asset information they need and check up on maintenance tasks from anywhere on the job site in real-time.
How manufacturing companies use CMMS software
In the manufacturing industry, a CMMS is a powerful tool to manage complex operations involving heavy machinery, production lines, and facility upkeep. Its primary role is to streamline maintenance procedures, improve equipment reliability, and reduce downtime.
Managing machinery and production lines
Manufacturing companies rely heavily on machinery to keep production running smoothly. A CMMS helps track each asset’s maintenance needs, making sure that the right work orders are created and executed promptly.
For instance, in a large-scale manufacturing environment, various machines may have different maintenance schedules. A CMMS ensures that preventive maintenance tasks get scheduled ahead of time to avoid unexpected breakdowns, which halt production and lead to costly delays.
Facility upkeep
A CMMS helps with more than just equipment management. Manufacturing facilities also need upkeep to ensure a safe and efficient working environment. The CMMS can manage tasks like HVAC system checks, building repairs, and safety inspections.
Preventive and predictive maintenance
A huge advantage of using a manufacturing CMMS is the ability to shift from reactive maintenance to preventive maintenance. Preventive maintenance (PM) involves scheduling and carrying out regular service on machinery to prevent failure.
A CMMS can track equipment usage, monitor asset conditions, and schedule preventive maintenance at optimal times for your operations schedule, helping improve the longevity of your equipment and avoid expensive repairs.
Predictive maintenance (PdM) takes PM a step further by incorporating the use of sensors to collect data from the machines and predict equipment failure. When integrated with IoT (Internet of Things) devices and collecting real-time maintenance data, a CMMS can analyze equipment patterns and send notifications to maintenance teams when a part is near failing.
Centralized data hub for informed-decision making
One of the primary benefits of using a CMMS in manufacturing is its ability to centralize all maintenance-related data. Maintenance managers can access detailed histories of each piece of equipment, track asset performance, and analyze trends in downtime or repair frequency.
Having centralized access to this data gives companies valuable insights into making informed decisions about equipment replacements, upgrades, and process improvements.
For example, if a specific machine breaks down frequently despite its regular maintenance, its CMMS data can help determine whether it’s time for a replacement or if further adjustments can be made to the maintenance process to help it remain active and productive.
This level of visibility allows manufacturers to optimize maintenance programs, allocate resources effectively, and reduce overall costs.
Benefits of using CMMS software for manufacturing applications
Using CMMS software in manufacturing provides a myriad of benefits to your company. Let’s break down the advantages that a CMMS contributes to manufacturing operations:
Increases equipment reliability
Machine health is essential to manufacturing operations. CMMS software improves asset uptime and lifespan by ensuring each asset gets the maintenance it needs. Maintenance teams can set up each piece of equipment in their CMMS with maintenance schedules based on OEMs (original equipment manufacturers) and historical data from the machine.
You can also upload specific notes, videos, pictures, and instructions for each machine, making it easy for teams to share information and perform maintenance tasks with more consistency.
Having this data easily accessible and automating preventive maintenance reduces the likelihood of unexpected downtime. Equipment reliability directly impacts productivity–when machines run consistently without issues, production stays on track, and companies can meet targets without delays.
Reduces equipment downtime
Equipment failure is the cause of 80% of all unplanned downtime for manufacturing companies, and this downtime can be extremely expensive. CMMS solutions help prevent equipment failure by ensuring that maintenance tasks are completed promptly.
A CMMS doesn’t just help with unplanned downtime, though; it also allows companies to minimize planned downtime by helping schedule maintenance during non-peak hours.
Cost savings
The International Society of Automation estimates that the average manufacturing plant loses 5-20% of its annual productivity because of unplanned downtime. By eliminating reactive maintenance and reducing the need for emergency repairs, a CMMS saves manufacturing companies a lot of money.
CMMS software also optimizes spare parts inventory management. Instead of overstocking inventory or facing shortages when parts are in urgent need, the software uses historical data to track spare parts usage and helps companies maintain appropriate inventory levels. This ensures that resources are used more efficiently and lowers operating costs.
Special considerations for manufacturing companies when choosing a CMMS
When selecting a CMMS, there is no one-size-fits-all solution. Manufacturing companies must start by evaluating their unique operational needs. The size of the facility, the complexity of the machinery, the nature of their products, and the number of assets being managed all influence the type of CMMS that will work best.
Here are some key considerations:
- Scalability: Manufacturing operations are typically designed for growth and adaptability so it is important to choose a CMMS that can scale with your company. A scalable CMMS allows you to add more users, integrate additional equipment, and adapt to new maintenance workflows on your own, without the need for costly system upgrades, reconfigurations, or vendor involvement.
- Easy integration: A CMMS should integrate seamlessly with existing systems you use to run your business, such as an ERP, EAM, or IoT devices. Make sure you select a CMMS that works with other software systems in your operations to avoid duplicating tasks or missing out on valuable insights.
- Mobile app access: Maintenance teams working on the production floor and across the plant or multiple facilities need mobile access to your CMMS. Mobile access ensures that technicians can easily update work orders and checklists, log repairs, and access data from anywhere on the job site.
- User-friendliness: Manufacturing teams have people with varying levels of technical expertise, so a CMMS must have an intuitive interface that everyone on your team will be able to use without the need for extensive training.
- Custom reporting: Manufacturing operations need data analysis to optimize maintenance. Customizable CMMS reports allow companies to pull specific insights–like maintenance costs, downtime events, or equipment performance. This helps teams track maintenance KPIs (key performance indicators) and other metrics to make informed decisions about asset maintenance.
- Regulatory compliance support: Compliance is a necessity for most manufacturing facilities. A CMMS should assist in documenting inspections, audits, and safety checks. Look for a system that allows for easy reporting to meet OSHA, ISO, or other industry-specific standards.
Top features any manufacturing CMMS should have
Beyond the special considerations for your business’s specific needs, there are several features and functions that any CMMS should have in order to be successful in supporting maintenance activities.
- Preventive maintenance scheduling: This feature automates triggers and notifications for regular maintenance based on predefined intervals or usage data, helping prevent breakdowns and extend equipment lifespan.
- Work order management: The ability to create, assign, and track work orders is a must for efficient task management. The system should notify technicians of pending tasks, track progress, and log completed jobs to maintain an accurate maintenance history.
- Asset management: Manufacturing companies handle a large number of machines and tools. A CMMS should have a robust asset management module that allows you to track the condition, location, and performance of each asset.
- Inventory management: CMMS software should help manage spare parts inventory by tracking stock levels, ordering parts automatically when inventory is low, and preventing delays in repairs due to part shortages.
- IoT integration for predictive maintenance: IoT sensors provide real-time data about equipment performance, and when integrated with a CMMS, this data can predict when a machine might fail. This feature ensures timely repairs before costly breakdowns occur.
- Reporting and analytics: Comprehensive reporting tools allow you to track performance, identify patterns, and make informed decisions. Features like customizable dashboards and KPIs give a real-time view of operations, helping companies optimize their maintenance strategies.
Get started with Limble CMMS
Choosing the right CMMS for your manufacturing operations can be transformative, improving equipment reliability, reducing downtime, cutting costs, and enhancing safety and compliance.
Limble CMMS offers the tools and features necessary to meet the demands of the manufacturing industry, providing a scalable, user-friendly solution that integrates seamlessly into your operations.
Ready to streamline your maintenance processes? Reach out to Limble CMMS today for a free demo and see how our maintenance management software can support your manufacturing needs.
