Modern production systems are the heartbeat not only of enterprises and businesses, but of our entire economy. This heartbeat gets irregular oreven stops, whenmachines fail. Preventing failure and ensuring an effective, seamless production process is the fundamental job of maintenance and asset management. In an age of increasing automation and interconnectivity,appropriate maintenance measures are becoming more and more important.
Production breakdown as a worst case scenario
A single mal-functioning machine or component can trigger adverse effects along the entire value chain. Resulting in costs not only for repairs and spare parts, but also in indirect costs, i.e. production shortfalls, delivery failures and reduction in quality. “Every plant manager knows: nothing can reduce operating income as fast as a standstill of production”, says Nils Blechschmidt, Managing Partner of ConMoto. Production loss over a prolonged period of time can even threaten the existence of a company, particularly of small and medium-sized enterprises.
Also businesses face increasingly complex challenges in internationally competitive markets. Firms, which are unable to meet delivery targets and quality standards, run the risk of weakening their market position or losing whole markets.
Maintenance as a strategic success factor
According to experts up to 60 percent of overall production costs are related to the efficiency of maintenance and asset management, the share varying from industry to industry. “Maintenance is more than a cost factor or a mere service function”, explains Blechschmidt, “it is a yardstick for employing a company’s capital diligently and profitably”.
In an age of digitization reliable maintenance that minimizes down-time, serves as a driver of productivity and is a strategic success factor, especially in capital-intensive industries like raw material processing, the chemical industry and automotive.
The ConMoto Consulting Group puts an emphasis on predictive maintenance to avoid production losses. Predictive maintenance analyzes a component’s status, the degree of wear and tear and calculates a date of prospective component failure – a point in time when the wear limit is reached and a module’s proper function can no longer be guaranteed. Blechschmidt puts it simply: “We make an effort to know in advance which machines will shut down at which point in time”.
Today Predictive Maintenance accounts for only 2-3 percent of all maintenance expenditure. This result is supported by the experience of more than 300 ConMoto projects in Maintenance and Asset Management. In real life companies in the industrial sector are still acting responsively, working with time-based models of periodical maintenance and inspection.
ConMoto supports its clients by devising and implementing economically viable maintenance strategies. These strategies establish an integrated order management system that aligns capacity planning and scheduling. This system is complemented by improved maintenance cycles, optimized machine running times and efficiency gains for the overall process organization. Another leverage point for efficiency gains is optimizing procurement of spare parts and Contractor Management. The overall aim is not only to minimize maintenance costs, but also to chart a course for sustainable gains in productivity and profitability.
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Always at the ready: giving machine stoppage no chance