10 steps to achieve world-class manufacturing

maintenance practices
Step 1 – Gather data and calculate downtime costs. Before you can successfully
transition to maintenance best practices, you’ll need to gather data to identify the scale
of the challenge. Assemble information on machine downtime, meantime between
machine failures, expenditures on parts, technology usage, technician response time
and the percentage of on-time deliveries. This will enable you to calculate the average
cost of one hour of downtime.

Step 2 – Determine the dollar value of maintenance. With an average per-hour

downtime cost estimate in hand, you can project how much money maintenance
improvements would save. You can make reasonable assumptions by applying the per-
hour cost of downtime to machine availability, determining how much value an increase
in availability will add to the organization. You’ll likely find that even a small increase,
such as 5%, translates into a huge improvement.

Step 3 – Analyze operational variables. When determining projected productivity

increases resulting from improved machine availability, it’s also important to factor in the
savings your maintenance operation can realize by addressing operational variables.
For example, take a look at how a better plan to handle critical spares, introduction of a
work order system and faster technician response time could impact availability.

Step 4 – Invest in a technology solution. As you’ll see in step 3, controlling variables

adds significant value, and a technology solution can make it easy to improve the
handling of variables across the board. A Computerized Maintenance Monitoring System
(CMMS) provides work order information and improves technician response time, also
lowering the mean time to repair and reducing downtime overall.

Step 5 – Start scheduling preventive maintenance. With a CMMS that enables you to
process work orders, you can easily monitor all manufacturing assets in your operation
and track critical parts and spares. This means you’re ready to schedule preventive
maintenance and generate checklists to manage maintenance tasks.

Step 6 – Deploy a scheduler planning function. As you transition from reactive

maintenance to a more proactive stance, you’ll need to schedule technicians’ time for
preventive maintenance and ensure that the right parts are available when needed. A
scheduler planning function is a critical tool for reducing downtime and maximizing the
value of preventive maintenance.

Step 7 – Introduce predictive tools. Preventive maintenance reduces downtime, and a

predictive maintenance checklist can improve machine availability even more. The type
of predictive tools you’ll need will depend on the equipment your team maintains.
Electrical equipment can be hampered by overheating, so a thermography tool can
prevent trouble before it results in downtime. Rotating equipment requires vibration
analysis, and aircraft need ultrasound scanning for leaks.

Step 8 – Move toward Total Productive Maintenance (TPM). After the predictive
maintenance plan is in place, the next step is to get operators involved in TPM. To
leverage operators’ familiarity with manufacturing assets, find simple solutions that enlist
operators in maintenance, such as keeping assets clean and freshly painted to aid in
visual inspection or installing sight gauges that enable operators to monitor fluid levels.

Step 9 – Implement a Reliability Centered Maintenance (RCM) strategy. Once you

have practices, technology and monitoring tools in place, you can begin practicing RCM
to drive downtime to even lower levels. With a clearer view of machine capabilities and
status, you no longer have to take equipment offline for preventive maintenance until
your data indicates imminent failure. You can maximize value with a cost-benefit
analysis of maintenance vs. productivity needs.

Step 10 – Bring in third-party technicians as needed. Achieving world-class

maintenance involves a cultural transformation, and with a shortage of skilled
technicians, it may be necessary to bring in third-party resources to establish metrics
and define processes. If you are looking outside your company to achieve the cultural
shift you require, make sure you get references from existing customers to ensure the
right fit with your organization.

Deploying Lean maintenance practices takes analysis, planning and skill – but above all,
it requires a commitment to move from a reactive to a proactive state of mind. By
following these 10 steps, you can implement world-class maintenance practices at your
manufacturing operation and significantly improve productivity.
Maintenance Report
8-Mar-2019•Knowledge

Create a report for your maintenance crew listing times and events that require
setup and/or takedown. The report can be grouped by date, event, facility or
service and filtered by criteria such as calendar, service, facility and event type
allowing your maintenance staff to more easily schedule their work.

This article shows you how to:

 Access the Maintenance Report

 Filter the Maintenance Report
 Reporting Start and End Times for All Day Events
 Export or Print the Maintenance Report

Access the Maintenance Report

You can find the maintenance report in the Scheduling & Activities folder, or
simply use the report search feature.

1. Hover over Reports and click View Reports.

2. In the search bar, type at least three letters of the word maintenance.
3. Click the result called Maintenance Report.

TIP: If you think you're going to use this report often, open the Scheduling &
Activities folder and click the star beside the Maintenance Report to mark it as a
favorite.

Filter the Maintenance Report

You can filter the maintenance report by:

Date, Calendar Category, Calendar, Service, Location, Facility Type, Facility,
Event Type.
 1. Click any of the filters and select the scope of the maintenance report

Click the button beside Include events without maintenance to further filter
your report. Yes show all events that conform to the other filters you have
selected, whether they require maintenance or not. No shows only those events
that conform to your filter settings and do require maintenance to be performed.

For 5.2.1 Release

You can also set how the report’s Header appears:

 First Page Only

 Every Page
 None

2. Click the Show filter to include the Supervisor, Staff, and the Extras that
are associated with the event, which Maintenance are required to set
up. You can also show each event's Conditions of Use, which is taken
from either the facility contract or the activity.
3. Click Preview to update the display at the bottom.
The report shows maintenance details of each event in the time range, including
the Setup/Takedown Time, Instructions, Event Time, Facility, Event, ID
(Rental, Contract or Event), Service, and Customer.

If Extras are selected under the Show dropdown, the name, quantity and times
that extras which maintenance must provide, in their corresponding rows.

Only extras that are considered equipment are shown on the report. Additional
extras, such as products, are not show.

Report Start and End Times for All Day Events

Maintenance Reports have more control over how they calculate start and end
times of All Day events. This helps maintenance staff schedule their activities
more accurately.

The start and end times of an All Day event are determined by your facility's
hours of operation.

If your facility does not provide hours of operation these times are based on the
instructor's available hours.
If neither your facility nor the activity's instructors have listed available hours,
these times are based on those of the Organization running the activity. A setup
period of 30 minutes and a takedown period of 15 minutes is applied to every
activity. The calendar will provide that time when the activity is schedule.

Export or Print the Maintenance Report

You can either export the report as a PDF, or print it.