for example, a machine keeps failing, you can look into its
historical work orders and estimate how much it will cost to
repair it again. With that analysis, you may discover that it’s
less expensive to fully replace it, and you can justify it in a
budget request based on your CMMS’ data. With everything
in one central dashboard, you can create a full picture of your
Best of all, you don’t need to invest in expensive new
assets in order to take advantage of the benefits of data.
For condition monitoring, for example, you can purchase
aftermarket sensors for your existing machines. With these
sensors, you can detect temperature fluctuations, analyze
vibrations and more. And, these sensors can come in handy
when you’re ready to take the next step from proactive to
Modern Maintenance: Beyond Proactive
With predictive maintenance (PdM), you can automate
condition monitoring processes with the use of sensors. PdM
analyzes historical data and real-time information so you
capture a more detailed picture of your assets’ working lives,
predicting a problem before it occurs. This means that you
have a safeguard to prevent a disruption to your production
schedule in between your scheduled PM. And, PdM
minimizes downtime as you can capture information while
equipment is running.
Some common types of condition monitoring includes
vibration analysis and acoustic analysis, and many CMMS
is able to also track asset runtimes, cycle counts, widgets
product and more. Whatever you choose to track, these
sensors enable you to automate these monitoring processes
and integrate them with your work. If, say, there’s a spike
in an assets’ temperature, a sensor will detect it, create a
work order in your CMMS and automatically route it to your
technician — even if it’s after-hours.
A well-designed PdM program analyzes historical data and
real-time information so you capture a more detailed picture
of your assets’ working lives without technician interference.
schedule, save money on unforeseen repairs and extend the
life of your assets.
Key Components In A CMMS
Both PM and PdM are effective at maximizing Overall
Equipment Effectiveness (OEE), but they won’t make a big
difference without a maintenance management system to tie it all
together. In addition to these advanced maintenance capabilities,
if you’re thinking about a CMMS, be sure to look for:
1. Automated workflows: When a PM or PdM work order
is created, you can create settings in your CMMS to
automatically route these new tasks to the appropriate
technician based on location, length of time, asset and
more. You can also create email notifications so nothing is
lost in the cracks, even if it’s after hours.
2. Easy, detailed reporting: With all of the data in your
machines, you want to make sure that your solution can
take that information to give you insights. Your maintenance
management system should be able to develop insights into
all your data and help you translate this information into
detailed reports for key stakeholders.
3. Accurate budget forecasting: By predicting when a piece
of equipment will fail or reach the end of its useful life, you
can then accurately project those expenses into your budget.
You’ll also be able to discover cost savings opportunities.
4. Information on the go: A mobile-friendly CMMS
will keep your technician on the plant floor without
disruption. And, many vendors have apps that incorporate
mobile functionality, such as photo attachments, QR
codes and more.
Each manufacturer’s needs are different. With that in mind,
there are key components that are absolutely (and universally)
necessary in a CMMS in order to support both PM and PdM.
In the end, however, choosing a solution that fits your long-term and short-term needs will yield the best outcome for
your team, your machines and your clients.
Paul Lachance is the Senior Manufacturing Advisor for