Increasing equipment
availability and performance,
Increasing product quality and
Reducing maintenance expense
• When was the last time we worked on this asset? Any Problem?
• Where did we buy this part last time? Who has their phone number?
• Is there a substitute part in the storeroom? Where is it?
• Is this equipment under warranty? Have we availed any?
• Any PM program and maintenance task? Are they done and effective?
• How much have all the repairs on this asset cost? Should we replace
it?
• When was the last time a part was used? Is it obsolete?
• What is the level of maintenance? Preventive or reactive?
Reactive or
unplanned
corrective
work (BDM)
Planned
Calibration corrective
PM maintenance
Maintenance
Processes
Lubrication Preventive
PM In CMMS maintenance
Engineering /
Spare Parts
maintenance
inventory
projects
Measuring the Process
To evaluate the success of maintenance
processes and your implementation as a
whole, key performance indicator’s (KPI’s)
need to be defined.
Common Measurements (KPI)
1. Planned vs. Unplanned (reactive) maintenance work orders
•2. Percent preventive of planned work orders
•3. Percent predictive of planned work orders
4. Percent downtime (unplanned)
•5. Backlog work orders
6.•Spare parts usage
•7. Maintenance cost
•8. Cost by equipment class ( Top10 highest maintenance cost )
9. Top10 List of most problematic equipment based on line downtime
10. Percent equipment efficiency, line efficiency, performance
efficiency, utilization, OEE, etc
•11. Percent equipment availability, reliability and maintainability
•12. Loss opportunity due to equipment failure or line downtime effect
Labor
Asset
Work
Management
Task or Procedures
Preventive Maintenance
Materials Management
Work Order Material Procurement
Labor
•The ability to keep a listing of employees and
position/craft
• The ability to assign an employee to a specific craft
• The ability to assign an employee to a specific
crew and / or shift
• The ability to assign standard man-hr and work
duration to a work order.
Asset
•N
• ameplate data (manufacturer, • •Configurable equipment class
model, serial) and / or type
• Asset code and Fixed Asset • •Asset cost
Number • •Warranty information
• Asset criticality • •Meters (used to trigger PM)
•S
• pare part code & list • •Safety procedures
• PM Activities or tasks • The ability to attach documents
• •Location or position or images that can be printed
•H
• ierarchy for rolling up cost with the work order
from the asset to area and
facility
Work Management
• Work Order No.
• Work order description
• WO details / procedures / work steps
• Work order priority
• Configurable work order type (PM, corrective, safety, etc)
• Problem, component, cause and remedy codes
• The ability to reserve materials planned on work orders
• The ability to plan crafts, shifts and employees on work orders
• The ability to record the equipment downtime
• Record planned vs. actual labor, materials and cost
• Safety procedures
• The ability to attach documents or images to the WO.
Task or Procedures
• Checklist of tasked to be performed
• Estimated hours
• Resource assignments
• Parts list
• Safety procedures
• Availability of the equipment
Implementation
To get CMMS to provide useful
information, it must be configured,
key data collected and entered,
and employees must be motivated
to use the system.
4’Cs of Data Collection
Report must
Data must be
be
“Correct”
“Complete”
Data
The above
collection
2Cs must be
must be
“Consistent”
“Continuous”
System Configuration
Data Data
collection Testing
Migration
• Note:
CMMS must be well tested first to find out if it performs “as advertised”
Make sure the CMMS
Training administrator and staff are
working full time with the
implementor or consultant.
The format of training should
be “role and process-based”
Do not use “Canned” data but actual
data from the area collected manually.
CMMS is one of the greatest tool
ever created by technical people
to elevate maintenance efforts to
a professional level.
Engr. Renato A. Santos
PRO Maintech Consultancy, Inc.
promaintech@gmail.com
0917-533-4927
