Prevent Production Downtime and Reduce Costs with Effective Maintenance of Equipment and Support Systems
In today’s competitive business environment, high productivity, quality and optimal costs are essential for the success of manufacturing companies. Smooth and reliable operation of production equipment and other systems is highly dependent on efficient maintenance.
For example, a company involved in the production of pharmaceuticals faced frequent, sudden machine breakdowns. This led to lengthy production downtimes, increased repair costs, reduced production volumes and delayed deliveries to customers. Implementing preventive maintenance enabled the company to save several million euros annually by reducing repair costs, optimizing production cycles and increasing productivity.
Effective maintenance management means optimally planning, implementing and documenting activities to keep production equipment and processes running reliably, which requires the right IT support. This allows companies to achieve several key benefits:
Increase Uptime (OEE/Availability). Consistent equipment maintenance can prevent most downtimes and avoid lengthy and costly repairs. Monitoring equipment condition, alerting for malfunctions and providing accessible digital service documentation ensures quick detection and resolution of issues. Periodic maintenance is scheduled at times that are least disruptive to production, maximizing operational efficiency and asset utilization.
Increase Productivity (OEE/efficiency). Reliable equipment with no unforeseen downtime ensures smooth production processes, which is essential for maintaining and increasing productivity. With consistent uptime, machines can run longer and produce higher volumes of products. This helps meet production targets on time, strengthening the company’s reputation and competitiveness in the market.
Reduce Waste (OEE/Quality). High product quality and repeatability are key customer requirements. Although defective products can be detected and removed through advanced quality monitoring, this incurs significant time and material costs. Regular maintenance and early detection of equipment issues can prevent most waste caused by equipment failures or tool wear.
Extend Asset Life. Regular and planned maintenance, based on actual equipment condition, reduces wear and tear on critical components and extends machinery lifespan. Although the financial benefits may not be immediately apparent, this approach can save substantial costs by reducing the need for replacements over time.
Reduce Maintenance Costs. Effective planning and implementation of maintenance can significantly reduce the cost of unnecessary and unexpected repairs. We can also reduce the number of emergency interventions, which are usually more costly and disruptive to production processes, thus achieving a lower total cost of ownership (TCO) for production assets.
Build a Knowledge Base. A comprehensive record of maintenance history is essential for improving maintenance effectiveness. This helps identify and analyze recurring problems, allowing for faster diagnostics, optimized maintenance schedules, more effective spare parts management, skills development within the maintenance team and improved decision-making on the cost-effectiveness of repairs or replacements.
Improve Safety. Safety is crucial in a manufacturing environment. Regular maintenance ensures that machinery and equipment are in proper and safe condition, reducing the risk of accidents that could threaten employee health and safety. Well-maintained equipment also minimizes the risk of hazardous breakdowns or leaks, improving overall workplace safety.
A key factor in achieving these benefits is an advanced software solution like MePIS MT, designed for efficient maintenance management in production.
Advanced Software Solution for Efficient Maintenance Management - MePIS MT
Based on years of experience in production automation and digitalization, Metronik developed MePIS MT (Maintenance) to address the maintenance challenges faced in diverse production environments.
The application’s core functionalities include managing maintenance-related system data, scheduling maintenance work for teams or individuals, handling requests, orders and activities, conducting analyses and reporting, and providing predictive maintenance using a knowledge base and artificial intelligence.
Unlike similar tools, MePIS MT stands out for its reliable, user-friendly operation, unique mobile interface and access to all information necessary for effective maintenance management and execution.
For more information about the solution for efficient maintenance management in production, contact Vanja Tomažič at vanja.tomazic@metronik.si.
