Manufacturers invest millions in machines and equipment. These high dollar assets provide the foundation of successful and efficient manufacturing, and yet many companies rely on a spreadsheet, a plastic binder hanging from a hook, and the memory and experience of employees to maintain that critical investment.
If a machine goes down, production stops. Work has to be re-routed, putting ship dates and orders at risk. If work has to be done by a partner company, production costs will skyrocket. Scrap, higher production costs and late shipments are common consequences of machine problems.
Modern shop floors can’t rely on spreadsheets, plastic sleeves, and memory for machine maintenance. Machine upkeep is a critical production process requiring a production control system like Quantum. Successful upkeep and maintenance incorporates process control and conformance, just like every shop floor operation, and should be linked to operations and scheduling to eliminate downtime and increase production velocity.
Control and Conformance for Machine Maintenance
When evaluating your current processes, consider the following critical elements of a successful machine maintenance program managed by a production control system:
- Schedules and Alerts for Required Maintenance
Machine maintenance is a critical production activity. If you aren’t following maintenance protocol, you risk machine downtime, failed audits, and unsafe work conditions. A scheduled maintenance program eliminates these risks. Support the shop floor with alerts and a system that removes the risk of using a machine due for maintenance – a common occurrence when the shop floor is under pressure to move product and meet deadlines when maintenance is scheduled.
- Revision-controlled Maintenance Instructions and Records
Machine failure is a risk when you rely on paper-based records or worse, memory, for maintenance instructions. Over time, maintenance requirements can change and employees retire or leave. You need accessible, revision-controlled maintenance and repair instructions that can be accessed when needed. Records, beyond initials on a spreadsheet, should be kept on maintenance activities. A robust maintenance program will protect your investment and significantly reduce machine downtime and production costs.
- Integrated Maintenance and Production Schedules
When you are investing millions in production machines, maintenance must be a priority. It should be done regularly to optimize machine output and eliminate unscheduled downtime. A successful maintenance schedule that won’t negatively impact production must be integrated with the production schedule. The production supervisor should know when there is work scheduled on a machine to route orders accurately, and ensure shipping and production deadlines are met. With a digital schedule and a production control system, maintenance can be scheduled ahead of time and work optimized to maintain production velocity.
A Program for Optimizing Machine-use
Even though industrial machinery is a critical component of manufacturing, especially make-to-order manufacturing, many companies consider machine maintenance an afterthought until a machine goes down or the shop floor fails an audit. Spreadsheets and plastic sleeves on the machine aren’t an adequate maintenance program, especially when the shop floor comes under pressure to increase output.
Quantum production control system provides seamless support for your machine maintenance program as part of your standard production process, eliminating unscheduled machine downtime, the risk of failed audits, and the stress of upkeep while optimizing scheduling for machines and production. All the benefits are part of the standard product.