FastMaint CMMS Software - Maintenance Management Software - From $995
Equipment & Facility Maintenance Work Order Software For Utilities, Manufacturing Plants, Industrial & Commercial Facilities
Work order time (duration) is not the same as equipment downtime.
Why? Because an equipment may fail at 1 pm and the work order to repair it is scheduled at 3 pm. The technician may do a temporary fix to get the machine running again while he waits for a part to come in stock. The work order is still open. The part comes in the next day and the work order gets completed the next day at 11 am. So the actual equipment downtime may only be from 1 pm to 4 pm and the next day from 10 am to 11 am when the work order is completed. This is about 4 hours of downtime. The actual time spent on the work order is 2 hours (3 pm to 4p m on the first day and 10 am to 11 am the next day).
Make sure that reports from your CMMS/ maintenance software are not confusing the two.
Ideally your CMMS/ maintenance software should have some way to log when an equipment is unavailable and also why it is unavailable. Equipment could be unavailable for a variety of reasons, many of which may have nothing to do with the equipment e.g. power problems, operators no available, assembly line issues, inspections, etc. This way you can separate the different reasons why an equipment is not available and collect actual statistics on downtime due to equipment problems.
Most new equipment these days have a way to create log files of activity that can be imported into the CMMS/ maintenance software. This makes it easier to collect the information and not depend on operator or maintenance personnel reports for equipment downtime calculation. Check the equipment manufacturer’s documentation to see if it is possible to have the equipment automatically export these logs (ideally as simple text files) to a common folder on your computer network. Once all these files are being regularly collected you can have your CMMS/ maintenance software regularly import them in. You may need to do some customization/ changes to these export files since each equipment manufacturer may have their own export format. Your IT Department may be able to help you create procedures convert all these different formats to a single standard format that your CMMS/ maintenance software or other analysis software can use.
How useful is equipment downtime information?
Being able to review equipment downtime information can help you identify potential causes that may need to be addressed and help reduce future downtime incidents. For example if you see monthly downtime spiking repeatedly for some equipment you will want to investigate why. Reasons could be as varied as improperly trained operators, poor maintenance practices, equipment close to end of its useful life, etc. Critical equipment when not available has effects felt organization wide – production may be lost, quality may suffer and customers may experience delays getting products/ services. Besides reviewing the downtime data you may wish to do some statistical analysis if it is especially critical equipment. Even if the CMMS/ maintenance software does not offer such statistical analysis tools, you may be able to export this data to third-party tools that can do statistical calculations (e.g. a Weibull Failure Analysis).
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