Monday Morning : CMMS averts a disaster.

From on the blog that i follow,  http://blog.mintek.com/Enterprise_Asset_Management/bid/31167/Real-Life-CMMS-EAM-Crisis-Avoidance

If you ever had doubt as to the true value of an maintenance schedules and preventive maintenance then this incident should convince you to look into a CMMS/EAM solution.

How it was discovered:

■Maintenance workers went out to the site to perform scheduled maintenance by replacing a filter on a generator used to convert steam into electricity
■When replacing the filter they noticed an oil leak
■The plant was immediately shut down until repairs were made
Had maintenance not been scheduled the leak could well have manifested itself into a disaster of nuclear proportions. Making sure maintenance is performed, equipment inspection and doing preventive maintenance are all part of an EAM.

Cost of parts - $10 plus

Cost of Labor - $ 100 plus

Cost of EAM - $ 10,000 plus

Cost of averting a nuclear disaster - "Priceless"

Share your stories with us of disasters you have or have not avoided using a CMMS/EAM solution.

Using a CMMS system to uncover the obvious

The top 3 low hanging fruits are:

1. Stopping the duplication of effort: This could include anything from writing the work to be done down in more than one location or having to fix the same problem over and over without really knowing the cause. For example, writing the work order down on your calendar and then also on a piece of paper to give to someone else to fix. Solution - STOP! Input information into a CMMS software just once, press the button and create a work order. Record results of job and include detail as to what was fixed, how it was fixed and what could have been done to prevent the problem.
2. Using the CMMS to Stop Fire-fighting: This refers to spending the majority of your time reacting to maintenance request instead of inspecting assets and identifying problems before they cause unscheduled repair work. Solution - Start scheduling inspections and preventive maintenance on critical assets and then move onto lesser priority assets. Work toward a 80/20 ratio of proactive vs. reactive maintenance work orders. Watch overtime drop like a rock.
3. Reduce energy costs: The biggest ongoing expense in most facilities is the utilities bill. Solution - Lower your energy cost 15-30% just by doing preventive maintenance like changing filters or lubing mechanical parts. When equipment is not well maintained they require more energy to operate

Top 10 reasons CMMS projects fail:

It was a cold morning in Eugene and i was going through a good website on CMMS and thought i will share this with the user.

1. 
   
   Project team members get sidetracked and project loses momentum
2. 
   
   The importance of implementation planning is underestimated causing implementation efforts to become uncontrolled and unfocused
3. 
   
   Project gets near completion, then sputters along with no final go-live and cutover
4. 
   
   Software selection requirements are based on current processes and existing software, rather than improved processes and new technology
5. 
   
   Implementation is focused too much on software; not enough on project objectives and new management practices
6. 
   
   Project is thought to be completed once software is installed and operational
7. 
   
   Software was selected based on a “perception” or a “feeling”, not based on facts
8. 
   
   Minor technical system difficulties stall the entire project
9. 
   
   Implementation efforts are primarily focused on processes with little emphasis on reporting and information needs
10. 
    
    Employees are asked to enter system data in their spare time

Cost Saving through CMMS

Sarjoo Prasads Commentaries on Essential Commodities Act, 1955 (Act No.10 of 1955) as amended up to date: And also Prevention of Blackmailing and Maintenance ... with All India control orders thereunderI was on the internet, i found something interesting and wish to share this on my blog so that my fans can read it.

These days many companies are scaling back on expenditures of any kind. And, why not? It just makes sense. Obviously, the severe economic downturn has impacted organizations across the United States and the Globe. Capital conservation has become the rule and cutbacks are inevitable. Yet, this is the just the kind of environment that completely justifies investment in Computerized Maintenance Management Software for organizations seeking to lower costs and protect vital plant and equipment assets. That’s your responsibility, right?
1 – Immediately Lower Operational Costs – Computerized Maintenance Management System (CMMS) Software provides an essential tool for managers working aggressively working to decrease downtime, inventory, material and contractor costs. Here’s how:
Less Downtime – Simple: Decreased downtime means increased production.  A 1% improvement in productivity has 10 times the positive impact than a 1% reduction in costs. Imagine the gain in a production facility running 24 hours per day:  A conservative estimated gain of 24 hours of production per year pours thousands of dollars to the bottom line.  Savings estimate: Downtime cost of $2,500/Hour x 24 Hours = $60,000 annual profit increase.
Reduced Inventory – Elementary: Asset maintenance management allows you purchase inventory and parts when you need them instead of relying on guesswork. Without CMMS Software, managers might not know what is in their stockroom, can’t find what they need and, frequently end up buying parts they already have. Of course, CMMS Software allows you to lookup parts, check stock and order only as needed. Savings estimate: Reducing an $800,000 inventory just 10% with a 10% interest rate results in an annual savings of over $8,000 in an annual profit increase.
Eliminate Contractor Costs – Smart: Managed maintenance keeps repairs in-house using a more efficient work crew. CMMS Software focuses crew time on work orders designed to keep the plant moving. Result? No maintenance logjams requiring expensive contractor time. This outcome creates not only a savings on labor but also a savings on parts! Savings estimate: Using a realistic 10% annual reduction in labor and material costs on a budget of $680,000 you return another $68,000 to the bottom line.
2 – Increase Maintenance Productivity Right Now – Better work planning and scheduling maximizes crew efficiency while focusing crew time on work orders designed to keep the plant moving.  Productivity increases of 10% to 20% using modern CMMS Software are standard. Maintenance managers know that saving just 60 minutes (12.5%) per day for each worker in a six-person crew at a $30/hr labor rate for 250 days/year can preserve $45,000 annually for the organization.
When implemented properly, a Computerized Maintenance Management System using CMMS Software can be a huge cost and time saving addition to your organization’s bottom line. Isn’t that what your objective is? 

But, with a prudently estimated return-on-investment (ROI) of over 1000% (yes, one thousand percent!), your CMMS Software investment is intelligent, wise and – urgent!

What does CMMS mean to maintainence