Maintenance and repairs are often perceived primarily as cost factors. However, since reliability management has become more important and has become a key strategic success factor for companies, this perception is slowly changing.
But of course cost is a major concern and much attention is being paid to reducing costs in maintenance operations. Fortunately, there are many adjustment screws here.
Read here which five cost drivers in industrial maintenance we have identified for you and how you can avoid them!
Cost driver #1: Lack of investment
Short-term cost-cutting measures in maintenance are likely to haunt your organization for a very long time. Plants, machines and electrical components must be regularly maintained, updated and modernized to avoid unplanned downtimes. However, companies often ignore problems with outdated software, manuals and documentation.
Cost driver #2: Machine downtime & missing KPIs
Unplanned downtime costs between $3,000 and $200,000 per hour. If a machine breaks down, production comes to a standstill. These situations put enormous pressure on the maintenance and repair staff, who are supposed to resolve the failure as quickly as possible or, at best, avoid critical incidents from the outset.
Predictive maintenance and the evaluation of machine parameters help to avoid downtimes. Digital tools and smart digital helpers support technicians with quick repairs and improve overall operational efficiency.
Cost driver #3: Missing or incomplete documentation
Missing machine documentation and repair instructions are a common problem in maintenance companies, especially when the experts with all the knowledge have left the company (brain drain, retirement). Exploded drawings and the parts list are also important components of proper maintenance documentation.
Cost driver #4: Slow & wrong decisions
The digitalized evaluation of your machine data offers the best basis for well-founded decisions based on solid numbers. According to a digitalization survey, 33% of survey participants manage, control and monitor their assets, such as production facilities, centrally. Another 37% are currently switching to digitalized evaluations and 36% are analyzing their company data systematically.
Cost driver #5: Overtaxed employees
Stressed and overworked employees make mistakes more often. They cannot carry out maintenance with the necessary care and accuracy and ignore or postpone planned (predictive) maintenance work.
Digital tools like Partium can help reduce repetitive and administrative tasks. They help to avoid incorrect parts orders and unnecessary trips to the warehouse, and are a good way to double-check whether the part in question is available or whether it is actually the right part.
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