Why Maintenance is important to your organisation
As someone involved in the maintenance of a company’s assets, which may include plant machinery, vehicles, long term hire equipment, stock and spares; you will be aware of the bewildering amount of guidance on the subject. You may well be new to the subject having just been delegated to look at your company’s asset portfolio, or given this task in addition to other operations work. But what ever the situation this short check guide will help you look at the macro questions which effect correct maintenance activity and asset management.
- Are all your assets on the computerised maintenance management system identified registered, and recorded, and how many are not being used?
- Do you know which assets present the greatest risk to your business in terms of: Business continuity, Health & Safety, Environment, Lost production output?
- Do you know the condition of all the assets and do you know the level of reliability?
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The key areas of maintenance are:
- Cost reduction and plant performance
- Spare parts and materials management/MROM (Maintenance Repair and Operating Materials)
- Equipment reliability programmes
- Planning and scheduling
Cost reduction and plant performance
MCP deliver maintenance cost reduction programmes which will reduce the total cost of maintaining your equipment in either a manufacturing or services environment. Maintenance costs reduction programme will typically deliver savings of 10-20% of a current maintenance budget. Our approach involves:
- Review of cost elements and drivers
- Workload and labour utilisation
- Contractor and contract costs
- Parts and materials management
- Purchasing policies
A typical initial review will require 3-4 days which can be followed by further support to help deliver cost savings.
Spare Parts and Materials Management
In many companies spare parts stock represents a major investment which should ensure that the right parts are always available when needed. However, in reality this is not the case and companies find that they have too much capital tied up and that equipment is stopped waiting for a spare.
Research by MCP indicates that on average savings of 20-25% can be achieved by revising the approach to spares management.
MCP services to support spare parts optimisation:
- Duplication and data cleaning (especially recommended before implementing a CMMS)
- Parts cataloguing
- Stocking strategies
- Parts cost reduction
- Establishing stock levels
- Key performance indicators
- Stores management and design
The AMIS Parts & Materials Management Audit is designed to assess the gap between current status and best practice. The assessment which usually requires 3 – 4 days, provides a summary of strengths and weaknesses over the key aspects of parts and stores management.
The outputs from the audit are:
- A series of benchmark scores
- Quantified savings
- Actions and next steps
MCP also provide regular scheduled public courses in spare parts and materials management, as well as providing training on your site at a time to suit your requirements.
Read Brian Tinham’s article in the Plant Engineer on Spare Parts – “Poorly managed MRO stores are costing plants serious money. Brian, with the help of Peter Gagg, examines systems, metjods, equipment and services that claim to help plant engineers.
Planning & Scheduling
Maintenance Work Planning and scheduling processes that are well designed and applied will result in high levels of labour, utilisation, reduced maintenance backlog. The development of a comprehensive work management system, which includes work planning, is a prerequisite for the design and implementation of a CMMS.
MCP provide support to companies to develop effective work management systems and also provide training in work planning and scheduling – Maintenance Planning and Scheduling Training Course.