Among buzzwords, a notable one is ‘World Class Maintenance.’ Besides asset management, ‘World Class Maintenance’ is about integrating data, people, and assets. It is said that following this strategy will lead organizations to the forefront of the Industry 4.0 revolution.

 What is World Class Manufacturing?

If something is ‘world class’, it is the best of the best. Regarding maintenance, it means the standards of your operation are within the top 5% key performance indicator (KPI) metrics. Things like downtime and work order completion rates must fall within that 5% for organizations to claim they have world-class maintenance practices. How do you reach this goal? By implementing and using Industrial Internet of Things (IIoT) technology in your day-to-day operations.

IIoT and Industry 4.0

While these two concepts aren’t the same, it is closely related. Industry 4.0 is the worldwide revolution in how things are done, and it’s all about digitization. The physical world is being copied into a digital world. This is achieved through the collection of data about physical objects.

Industry 4.0 is an ideology, while IIoT is the practical way digitization is done. It refers to integrated instruments, sensors, and other technological devices to enhance industrial and manufacturing processes. IIoT gives way to reliability-centered maintenance. Let’s have a look at what that is.

Source: Automation Insights, [s.a.]
Reliability-centered maintenance (RCM)

RCM is a corporate-level maintenance process used to optimize an organization’s maintenance system. The goal of an RCM strategy is to implement a particular maintenance strategy on every asset of a facility.

In the industrial industry, reliability-centered maintenance as a section of World Class Maintenance means the following:

Start with an assessment of asset criticality that informs you which assets are functionally needed for operation. Next, select devices to use and the assets to monitor. Then, make sure you train your staff to use the new software and technology and how to install and authorize vibration sensors.

 

Source: Reliability-Centered Maintenance Methodology and Application: A Case Study, 2010.

 

How to Build a World-Class Maintenance Department

There are several steps in building a World-Class Maintenance department. It’s about linking assets, teams, and data to the advantage of all three. Teams can use the data to reach higher capacity. When data is easy to access, teams are able to strategize for reliability.

To build a World-Class Maintenance department using metrics means that your maintenance team attains the highest KPIs.

  • Are more than 80% of completed tasks planned maintenance?
  • Is your equipment available 90% or more of the time?
  • Is the amount of reactive maintenance less than 10%?
  • Are you able to comply with preventive maintenance (PM) 95% of the time?

To achieve World Class Maintenance means you need a partner in reliability— a vendor you work with that provides sensors, software, services, training, and tools.

Eagle’s tools to help you

The Machine ledger in PROTEUS MMX is a Manufacturing 4.0 feature developed to help manufacturers meet world class manufacturing excellence. It allows managers to monitor the maintenance of machinery revealing root causes failure reasons. It is viewed through the asset data and shows when maintenance occurred, when breakdowns occurred, when additional maintenance was done, and when the scheduled maintenance was supposed to occur.

Benefits of the machine ledger:

  • Allows the user to view the history of component replacement within a specific piece of equipment.
  • By breaking down the equipment’s BOM into an expanded chart view, you can visualize all of the failures within a given year.
  • You will also be able to view all scheduled and performed preventive maintenance.
  • 52 weeks machine history overview.
Your partner in World Class Maintenance

At Eagle Technology, we strive to help manufacturing plants, warehouses, and facilities achieve World Class Maintenance. Our Computerized Maintenance Management System (CMMS) will assist in strategizing your maintenance operations. We integrate with partners who provide wireless vibration sensors with excellent condition monitoring capabilities. Our data analysis services, training, and implementation can help with everything from expansions to multi-site deployment. Eagle strives to get you into the top 5% of maintenance KPI goals.

If you are ready to transform your everyday maintenance to World-Class Maintenance, email us, give us a call at +1 (262) 241-3845, schedule a demo, or get a free trial of Proteus MMX.