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Equipment of malfunctions in any facility are unpredictable, and in the facility management world, such occurrences impose a chaotic firefighting situation that eventually burns your budget. This old-fashioned run-to-fail system ensures serious interruptions in the course of operations, deadlines, and astronomical costs of emergency repair.
To avoid such expensive surprises, industry pioneers are quickly changing their reactive habits into data-oriented, proactive maintenance methods. With this ability to preempt and fix root causes, prior to disastrous failures to take place, organizations can cut down their downtime significantly and add to the lifespan of their equipment.
To overcome the transition between reactive chaos to proactive success, one will need a formidable digital command center such as Cryotos CMMS. Our intelligent platform automates your preventative scheduling and empowers your floor technicians, ensuring your unforeseeable processes become a well-organized operation.
Reactive maintenance, also known as run-to-fail or breakdown maintenance, is an asset management method where repair is only initiated after an equipment has failed or even broken down.
This is because of the traditional operational philosophical thinking of, if it is not broken, do not fix it and there is no upfront planning, condition monitoring or pre-emptive action. You just sit and wait until the asset breaks down and then you send a team to repair it.
In a reactive approach to maintenance, work is typically divided into three distinct categories:
The reactive maintenance is not absolutely outdated, but it should be used strategically. A run to failure strategy is quite reasonable, and even economical, when the risks are low, the cost is cheap, and the replacement is simple (such as a lightbulb or a low cost, simple hand tool). It is also logical to support the equipment that has redundant systems when the failure of one device will not affect the safety or the usual output.
Using reactive maintenance in the case of your critical and high value assets is a disaster. The drawbacks include:
Proactive maintenance is a futuristic approach that aims at predicting, detecting and eradicating equipment breakdowns prior to their occurring. This method will prevent a machine from going bad rather than waiting until a machine malfunctions, and this is because the root causes of degradation are dealt with, which include misalignment or dirty lubricants.
This approach is the umbrella term referring to three different approaches that are data-driven:
A shift towards an active mentality means an initial investment in technology such as a CMMS, which will have colossal returns in the long term:
Although the two strategies are part of a balanced facility management program, they are incredibly different from philosophies and working effects. The following is the way they compare with each other:
The Verdict: A Blended Strategy World-class maintenance programs don't choose just one; they use Asset Criticality Analysis to blend them. Dedicate your proactive efforts (70-90% of your workload) to critical, high-value assets, and leave your low-cost, easily replaceable assets to a reactive approach.
Factories and facility management industries are fast giving up the practice of run-to-failure due to its being an unsustainable drain on the budget. The companies are discovering that controlling the health of their equipment has enormous long-term payoffs, which are fueled by the following core reasons:
The process of leaving behind a culture of reaction and firefighting and becoming an active powerhouse does not occur overnight. The following is a step-by-step to implement your facility to the right track:
You cannot keep what you are unaware that you have. Register all the equipment in your plant with Cryotos. Scrutinize the fundamental data, such as make, model, location, historical repair data and the present condition of health.
Not every asset is made the same way. Determine your Critical Assets - the machines where failure is not an option because it would be a safety hazard, the machines that would bring the whole production line to its knees, or whose replacement would cost an astronomical amount. Concentrate on your active initiatives in this regard.
Eliminate the guesswork of maintenance. Install periodic PM (Preventive Maintenance) alerts in your CMMS. Both 90-day inspection and a 10,000-hour lubrication (among others), the software will automatically create work orders when it is due.
The efficiency of a strategy is as good as the team implementing the strategy. The mobile app is used by train technicians in instant reporting. With the ability to make notes, post photos of parts that have been used, and close the work orders through their smartphones, you will be able to get real-time access to the health of your facility.
Get rid of the unsightly spreadsheets and paper binders. Cryotos CMMS is your digital command center, the key to the proactive strategy:
Cryotos removes the guessing game, and the unpredictable breakdowns become a very structured cost-saving operation.
The final key to reducing expensive downtimes and increasing the life of your equipment will be to switch the chaotic reactive approach to a proactive strategic plan of preventing major failures. With the help of the right digital tools, you can finally get your facility in shape and transform the unexpected fixes into expected savings.
Tired of paying to be put out of business? Find out the ways Cryotos CMMS can be used to automate your proactive maintenance audit and defend your critical assets now.
