{"id":1019,"date":"2021-10-05T18:09:43","date_gmt":"2021-10-05T22:09:43","guid":{"rendered":"https:\/\/aliidesign-dev.com\/sigga\/5-tactics-to-turn-around-reactive-maintenance\/"},"modified":"2024-06-12T13:58:38","modified_gmt":"2024-06-12T13:58:38","slug":"talento-departamento-de-manutencao-0","status":"publish","type":"post","link":"https:\/\/www.sigga.com\/pt-br\/5-tactics-to-turn-around-reactive-maintenance\/","title":{"rendered":"5 t\u00e1ticas para reverter uma cultura de manuten\u00e7\u00e3o reativa"},"content":{"rendered":"

The notifications keep rolling in and yourplant maintenance team is stretched thin to keep production in business.You know you need to get ahead of the madness, but thebreakdowns and ad hoc requestskeep taking precedence and the backlog is ever-growing. If you can relate to this situation, then it\u2019stime to tackle some strategies to turn the situation around.In this article,we\u2019ll cover thecauses of areactive maintenance culture andoutline several effectiveSAPplant maintenance strategies toget started on the path to reliability.<\/span><\/p>\n

<\/p>\n

Index<\/p>\n

Challenges of a Reactive Maintenance Culture<\/a><\/p>\n

Under-planning<\/a>
\nOrganizational Structure<\/a>
\nSkilled Labor Shortage<\/a><\/p>\n

5 Tactics to Build a Proactive Maintenance Culture<\/a><\/p>\n

1. Free Up Your Existing Staff<\/a>
\n2. Invest in Dedicated Functional Roles<\/a>
\n3. Organize and Train for Success<\/a>
\n4. Work on Data Quality and Capture<\/a>
\n5. Establish Key Metrics<\/a><\/p>\n

ATurnaround Story<\/a><\/p>\n

How Sigga Can Help<\/a><\/p>\n

Challengesof a Reactive Maintenance Culture<\/span><\/p>\n

Whether you inherited a reactive maintenance culture when you took the job or fell into the reactive pattern due to labor shortages, as a maintenance manager, you are well aware that preventive maintenance can help you avoid breakdowns and will cost you less in the long run. But, as often the case, the urgency of priority break-fix work means all-hands-on-deck to get production lines back up. This comes at the expense of completing inspections and preventive work. Why do companies end up with a reactive maintenance culture?<\/span><\/p>\n

>Under-planning<\/p>\n

The lack of creating robust preventive maintenance plans is a common cause of reactive maintenance cultures. An incomplete set of planned work orders or worse yet, no planned work orders, results in preventive tasks NOT getting accomplished and a much higher propensity of equipment breakdowns.<\/span><\/p>\n

According to theMarshall Institute, A MeasuredApproach to Uptime<\/a>, “It is widely accepted in the maintenance industry that a well-planned Work Order is about 3 times less expensive than the same unplanned reactive Work Order, and that Emergency repairs may cost as much as 5 to 7 times more than planned work, which can obviously have a huge impact on the bottom line”.Considerthatthe cost impact is largely wasted timein boththe productionand maintenanceteams.<\/span><\/span><\/p>\n

Another reason for preventivework not getting accomplished is the lack ofcoordinationwith productionto shut down the machine for the task.<\/span><\/p>\n

Incomplete, inaccurate, or insufficientnumber of planned work ordersresults in wasting time andthe organizationlosing trust in theplanned work order criticality. The result is adownward spiral ofequipment deterioration and growth inbreakdowns and correctivemaintenance requirementsovercoming the abilityof the existing staff toaccomplish preventive work.<\/span><\/p>\n

>Organizational Structure<\/p>\n

For plant maintenance planning and work order management in SAP, the process can be especially tediousleading to offline workarounds to complete the work and as a result, poor quality and incomplete data in SAP.Many companies abandon the use of SAP PM altogether.<\/span><\/p>\n

The lack of data in SAP, leads to a lack of data to support the planning function. History records providethe information needed to determine how long a maintenance task should take andhow frequently assets breakdown.A good preventive maintenance program requires good data to be effective.<\/span><\/p>\n

According toDoc Palmer\u2019s Maintenance Planning and Scheduling Handbook<\/a>, \u201cImplementing proper planning and scheduling can improve the productive maintenance time of a typical organization from 25-35% to 50-55% – almost doubling the ability to get work completed.\u201dGiven staffing shortages, optimizing the use of your current staff iscritical.<\/span><\/span><\/p>\n

>Skilled Labor Shortage<\/p>\n

Theskilled labor shortage<\/a>has been an issue for years and is only getting worse. It is becoming a critical issue for production and maintenance operations.ADeloitte study<\/a>found that the \u201ctop business impact of pervasive job openings [is the] inability to maintain or increase production levels to satisfy growing customer demands. Sixty percent of respondents ranked the skills shortage as having a high or very high impact on productivity over the next three years.\u201d<\/span><\/span><\/span><\/p>\n

It is also a key driver of companies becoming more reactive in the maintenance function as the limited resources are spread thin to cover the workload. Even contract resources are challenging to hire and retain.<\/span><\/p>\n

The overall cost impact of a higher proportion of reactive work can be significant to an SAP plant maintenance organization.From our whitepaper,Unleash the Power of SAP and Save<\/span><\/a>, you can see how just a 30% shift of reactive maintenance to planned maintenance can save a company over 10% in direct maintenance costs, nonetheless the long-term impacts of greater equipment uptime and improved staff availability.<\/span><\/span><\/p>\n

\"Maintain<\/p>\n

5TacticstoBuild a ProactiveMaintenance Culture<\/span><\/p>\n

Now, we know how wegot into a reactive state, how do we dig ourselves outwhilecovering the day-to-day maintenance requests?<\/span><\/p>\n

1. Free Up Your Existing Staff<\/p>\n

Withlimited resources, everyone\u2019s time is valuable.Time wastes need to be eliminatedto free up resources to accomplish more work such as preventive tasks to reduce the backlog.One of the first things to do is awrench time evaluation<\/a>.In order tounderstandwhere technicians are spending their time,the nature of delays,and time wastes.Then start to address the big drivers of inefficiency.<\/span><\/span><\/p>\n

Providing technicians with a mobile device cuts out significant travel time and physical steps during the day. The technician can receive work orders at the job site and send notifications while staying at the site. A mobile work order app can also significantly reduce administrative tasks for the technicians and data entry staff as compared to using paper-based work orders. For example, cutting-out getting in line at a computer terminal to make entries.<\/span><\/p>\n

Many administrative, repetitive tasks can be replaced with automation to free up resources for more valuable work.From planning to scheduling and completing maintenance tasks, today\u2019s digital technologies are designed to create efficienciesso that the whole staffcanbe utilized in more effective ways.<\/span><\/p>\n

2. Invest in Dedicated Functional Roles<\/span><\/p>\n

Good maintenance planning is key to making the shift.According toDoc Palmer, the author of Maintenance Planning and Scheduling Handbook<\/a>, the benefit of good planning and scheduling can result in a 57% improvement in wrench time and up to 90% schedule compliance.<\/span><\/span><\/p>\n