Maintenance
What is the CMMS system?
CMMS or Computerised Maintenance Management System is a class of IT systems responsible for repair management and maintenance in an enterprise, institution or organization. A system designed to help and improve the work of maintenance departments or services. In the industrial environment, the use of this type of tools is absolutely justified and is becoming more and more popular.
History and Evolution of CMMS Systems
The first CMMS system was designed in the 1960s when companies began to realize the need for more effective management of machine and equipment maintenance. Initially, the systems were simple applications that allowed for the recording and tracking of maintenance work. Over the years, with the development of information technology, the maintenance system has become more advanced, offering a wide range of functions and integration possibilities.
In the 1980s and 1990s, the maintenance system gained popularity due to the development of personal computers and ERP (Enterprise Resource Planning) software. Currently, modern CMMS-class systems are fully integrated solutions that use technologies such as the Internet of Things (IoT), artificial intelligence (AI), and big data analytics to further increase the efficiency of maintenance management.
Modern Trends in CMMS Systems Development
Internet of Things (IoT) and CMMS System
Integration of IoT technology with CMMS systems allows for the collection and analysis of real-time data from various sensors installed on machines and equipment. This enables CMMS systems to automatically generate work orders based on actual data about the technical condition of machines, which allows for more efficient maintenance management and minimizes downtime.
Artificial Intelligence (AI) and Predictive Analytics
The use of artificial intelligence and predictive analytics in CMMS systems allows for predicting failures and optimizing the planning of maintenance work. AI algorithms analyze historical data and current information to identify patterns and predict when machines may fail. This enables companies to take proactive maintenance actions, preventing downtime and reducing costs.
Mobility and Data Accessibility
Almost every modern maintenance system offers access to data and functions via mobile devices such as smartphones and tablets. This allows employees to manage maintenance tasks from any location, increasing their efficiency and enabling faster response to failures. The mobility of CMMS systems also improves communication and collaboration among team members.
Integration of CMMS Systems with IT Infrastructure.
Integration with ERP Systems
CMMS systems are often integrated with ERP systems, which enables better management of enterprise resources. Integration with ERP allows for synchronization of data related to inventory, purchases, finances, and other areas of activity, resulting in more efficient enterprise management. Thanks to this, all departments have access to current information, which allows for better planning and decision-making.
Integration with SCADA and MES Systems
CMMS-class systems can also be integrated with SCADA (Supervisory Control and Data Acquisition) and MES (Manufacturing Execution Systems). Integration with SCADA allows for real-time monitoring and control of production processes, while integration with MES enables the management of production operations at the executive level. Thanks to this, the CMMS system can automatically respond to changes in production processes and generate appropriate work orders.
System CMMS
Computerized maintenance management system (CMMS)
The CMMS system automates most of the logistics functions performed by maintenance personnel and management. These systems have many possibilities and advantages over manual maintenance tracking systems.
Depending on the complexity of the selected system, common CMMS features may include:
- Generate work orders, prioritize, and track by component.
- Historical tracking of all generated work orders, which can be sorted by equipment, date, respondent, etc.
- Tracking of scheduled and unplanned maintenance.
- Storage of maintenance procedures and all warranty information by component.
- Retention of all technical documentation or procedures by component.
- Real-time reports of current work.
- Generate preventive maintenance orders based on calendar or time of execution.
- Track budget and labor utilization by component, as well as shortest, median, and longest work order close times by component.
- Full control of spare parts with the possibility of automatic re-ordering of materials to the warehouse.
- Mobile application facilitating data entry and generating work orders.
- External options for calling / sending the service.
CMMS system
What are the benefits of implementing a CMMS system?
One of the biggest advantages of CMMS is the elimination of paperwork for work records and manual tracking of activities, which allows staff to become more productive. It should be noted that the functionality of the CMMS lies in its ability to collect and store information. The CMMS does not make decisions, but rather provides the maintenance services with precise information influencing the operational efficiency of the facilities.
Benefits of using the CMMS system
Thanks to the CMMS, it is possible to optimize the outlays for the maintenance of assets as a function of the failure rate analysis of machines and devices, the failure of which may have an impact on the threat to human life or environmental contamination.
Examples of CMMS Systems Success in Various Industries
Manufacturing Industry
In the manufacturing industry, the implementation of a CMMS system allows for a significant reduction in the number of failures and downtime. With effective maintenance management, companies can achieve higher machine availability and increase production efficiency. Additionally, data analysis from the CMMS system enables optimization of maintenance scheduling, leading to further cost savings.
Petrochemical Industry
In the petrochemical industry, a CMMS system enables refineries to effectively manage maintenance of infrastructure and optimize production processes. With integration with SCADA and MES systems, companies can monitor and control production processes in real-time, allowing for quick response to any technical issues. Automation of maintenance processes helps reduce the number of failures and downtimes.
CMMS in practice
The CMMS system is a tool designed for practical use in maintenance. Depending on the sophistication of the software package, different analytical tools are available for the enterprise. The system allows, inter alia, to:
- Digitization of the maintenance department and minimization of paper documentation, which significantly improves the work of employees and allows for better organization of the maintenance department.
- Efficient management of warehouse, production resources and spare parts.
- Planning of preventive and service activities.
Increasingly, CMMS software packages are hosted by vendors in the cloud and available on the network in the SaaS model. Increasingly, attention is paid to the various requirements related to the maintenance and management of infrastructure. Therefore, there are various applications on the market that can help you control the day-to-day operation of your facility. Due to the disadvantages of local CMMS systems, we observe the growing popularity of SaaS (Software as a Service) solutions, which are becoming more and more available in terms of infrastructure, price and access to high-speed internet connections. That is why every company can afford the possibility of implementing a CMMS system in the cloud.
SaaS software is the most advanced solution that ensures automatic configuration of applications and servers, makes IT infrastructure requirements negligible, and allows you to maintain all the advantages of a local CMMS system, while significantly reducing costs and effort related to software maintenance.
Does the CMMS pay for itself?
Computerized maintenance management software varies in complexity, cost, and industry specificity. It is important to remember that CMMS is sometimes interchangeable with enterprise asset management (EAM) systems. However, according to experts, EAM solutions usually provide better functionality for managing various resources, such as physical machines or IT assets, which can be centrally accessed throughout the enterprise. On the contrary, CMMS is usually limited to physical assets in a network of small facilities or even at a single location.
Currently, CMMS systems and EAM do not exclude each other. They are often integrated with each other and with ERP systems. Although the basic functions of CMMS developed 25 years ago are still the foundation of such programs, we are observing the development of mobile technology and the use of cloud computing.
The cost of equipment downtime and production stops is huge, so prevention and frequent maintenance are very important to minimize the risk of failure. The maintenance department should also control the contents of the spare parts warehouse, because in the event of a machine breakdown, you may find that faulty parts are out of stock, so you have to wait two weeks before they can be delivered. Such a situation should not occur, as it will significantly increase the downtime of the equipment, and thus increase the cost due to the machine being left out of the production process, or cause production to stop for critical equipment.
How do you get started using a CMMS?
If you have decided that a CMMS is right for you, the most important thing now is to find one that meets your requirements. A key step is to do thorough research – you can find articles comparing different systems on the internet, which makes the choice much easier.
What should you pay attention to? First and foremost, the available functions, the possibilities of configuration for your specific needs and the price. Manufacturers usually offer demos of their systems so that you can get a practical feel for how they work.
If you think your UR department needs optimisation, but need concrete evidence to convince the Board, it is worth taking advantage of a free consultation before purchasing a system. At Eurotronic, we meet your needs with support and a dedicated offer tailored to the individual contractor.
Translated with DeepL.com (free version)
Supporting the work of maintenance workers
Computer systems have been developed to support and streamline the work of maintenance workers, and companies are increasingly using them. An example of such a system is the CMMS. These systems provide access to all information about the machinery park, give the ability to report a fault or current breakdown, and allow personnel to manage it. One of the main advantages of this system is the ability to control the company’s inventory and equipment by creating a structure in the system and adjusting it.
