Wireman - Successfully Utilizing CMMS/EAM Systems: Maintenance Strategy Series
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www.terrywireman.com
TLWireman@Mindspring.com
Reliabilityweb.com
Maintenance Strategy Series
Volume 4
Successfully Utilizing CMMS/EAM Systems
Terry Wireman
ISBN 978-1-939740-13-7
Copyright 2013 Reliabilityweb.com
Printed in the United States of America All rights reserved.
This book, or any parts thereof may not be reproduced, stored in a retrieval system, or transmitted in any form without the permission of the publisher.
Opinions expressed in this book are solely the authors and do not necessarily reflect the views of the Publisher.
Publisher: Terrence OHanlon
For information: Reliabilityweb.com
www.reliabilityweb.com
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TABLE OF CONTENTS
Maintenance Management Strategy ComponentsAssessing Maintenance Organizational Issues
Maintenance Organizational Attitudes
Maintenance Management Maturity GridMaintenance Planning
Maintenance Work Orders
Computerization of Manual Systems
Application of CMMS/EAM SoftwareDo I Really Need a CMMS/EAM System
CMMS/EAM System Check Sheet
Selection Tips1. Develop the Project Plan and Resource Requirements
2. Update All Current Records
3. Software Installation
4. Data Entry/Migration
5. System Introductions and Updates
6. CMMS/EAM System Training
Common Selection and Implementation ProblemsProper Staffing
Asset UtilizationEAM A ReviewIntroduction
Standard Cost Justification
Detailed Cost SavingsCMMS/EAM System Trends
ISO-9000 Certification
More Distant Future
The Far Distant Future
ConclusionCMMS/EAM System ProblemsEquipment SubsystemAre We There Yet?
Who Will Feed the Monster?
Downsizing or Dumbsizing: Which?
The Challenge of ChangeEquipment Efficiency Case Studies
Overall Equipment Effectiveness Case Studies
INTRODUCTION
Volume 4 CMMS / EAM Systems
In this volume, the topic of a computerized maintenance management system (CMMS) is discussed. In the first volumes of the Maintenance Strategy Series, almost all of the documentation necessary to management maintenance can be handled manually. However, with the addition of the maintenance work management processes in the last volume (Volume 3 of the Maintenance Strategy Series), the documentation and data analysis necessary to be efficient has increased.
It is still possible for some maintenance departments to manage their information manually. However, it is more efficient to use a properly-designed computer system to accomplish these tasks. Continuing with manual systems would be analogous to a companys accounting department still trying to utilize pens and lined ledger paper to track the company financials. Given the current stage of computer technology, it is much more logical to use a computer system to track and manage the necessary business information to manage maintenance properly.
A computerized maintenance management system is designed to simplify the data collection and analysis. As will be explained in this text, the basic modules of the CMMS are designed to facilitate the management of the various components of maintenance, such as:
- Preventive maintenance
- MRO inventory and procurement
- Work order management, including the tracking of
- Labor costs and information
- Material cost and information
- Contracting cost and information
When the CMMS is utilized across multiple plants, and corporate managers use the data to manage the assets at an enterprise level, the system acronym changes to an EAM system or Enterprise Asset Management system. This text will help the reader differentiate between the two types of systems and provide guidelines on when to use each type of system.
The text contains valuable information that will help any one using a CMMS / EAM system, whether they are in the selection, implementa- tion, or utilization phase with their system.
OVERVIEW
The Maintenance Strategy Series Process Flow
Good, sound, functional maintenance practices are essential for effective maintenance / asset management strategies. But what exactly are good, sound, functional maintenance practices? The materials contained in this overview (and the overview for each of the volumes in the Maintenance Strategy Series) explain each block of the Maintenance Strategy Series Process Flow. They are designed to highlight the steps necessary to develop a complete maintenance / asset management strategy for your plant or facility. The activities described in the Process Flow are designed to serve as a guide for strategic planning discussions. The flow diagram for the Maintenance Strategy Series Process Flow can be found at the end of this overview.
Authors Note
Many individuals may believe that this type of maintenance strategy program is too expensive or time consuming to implement, especially when there are advanced predictive or reliability techniques that might be employed. Yet there is a reason for the sequencing of the Maintenance Strategy Series process flow. If attempts are made to deploy advanced techniques before the organization is mature enough to properly understand and utilize them (basically, the I want results now short-term focus), they will fail. The reason? Developing and implementing a sustainable maintenance / asset management strategy is more than just distributing a flow chart or dictionary of technical terms. It is an educational exercise that must change a company culture. The educational process that occurs during a structured implementation of basic maintenance processes must evolve into more sophisticated and advanced processes as the organization develops the understanding and skills necessary.
If an individual is to obtain a college degree, it may involve an investment of four or more years to achieve this goal. Likewise, if a company is to obtain an advanced standing in a maintenance / asset management strategy, it may take up to four years. It is not that someone cannot, through years of experience and education, design their maintenance / asset management process in a short time period. It will, however, take the entire organization (from senior executive to shop floor employees) this amount of time to become mature in their understanding and utilization of the process. Although there will be incremental benefits achieved along the journey to maintenance / asset management excellence, the true benefits are not realized until there is a complete organizational focus on maximizing all aspects of the investment in the assets. It is this competitive focus that separates long-term, sustainable success from a short-term flash of improvement.
Figure I-4 Work Order and MRO Cost Relationships
In the beginning, it is necessary for a plant or facility to decide it is necessary to improve their maintenance / asset management strategy. The business reason for the needed improvement can be multi-faceted, but would likely include:
- Poor Return On Investment (ROI) for the total plant or facility valuation
- Poor throughput for the design of the plant
- Inability to meet production demands
- High cost of occupancy for a facility
- Excessive downtime
- Production inefficiencies
Once the decision has been made to develop / improve the maintenance/ asset management strategy, the Maintenance Strategy Series process flow diagram should be followed. It begins with Preventive Maintenance.
1. Does a PM Program Exist?
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