Maintenance Process & Efficiency Audit

Maintenance Process & Efficiency Audit

Many Maintenance Operations are struggling with high emergency (unplanned) to planned work order ratio, huge backlog, lack of sufficient resources, constant work interruptions, not having parts when needed, recurring failures and much more. In these lean times, when more is expected from fewer resources, having a highly efficient maintenance program with thoughtful planning is the key to success. 

The Martin Technical Maintenance Process & Efficiency Audit will identify and test the critical components of your maintenance program, create a gap analysis, suggest practical corrective actions and provide a compass for future planning.

Conducting a Maintenance Efficiency & Process Audit has a Very High and Quick Rate of Return

rate of return on a maintenance audit

The Rate of Return for a Maintenance Efficiency Audit is typically very high due to the relatively low cost of investment compared to the savings potentials.  Customers typically save tens to hundreds of thousands of dollars within the first year alone and continue to save the same or higher amounts in the following years.  No two companies or audits are alike, so it’s virtually impossible to predict ahead of time what your savings will be, but the following are typical savings that we find:

Maintenance Inventory:    10 - 30% of your annual inventory dollars
Preventive Maintenance:  20 - 30% in your preventive maintenance expenditures
Other Areas:                     10 – 30% savings

benefits

Some of the benefits of a maintence process and efficiency audit include:

- Cost Reduction - Reduce Downtime - Reduce Maintenance Emergencies - Improve Equipment Condition/Reliability

- Improve Planning & Scheduling - Improve Inventory & Purchase Processes - Energize Maintenance Staff

 

objectives

Objectives for a maintenance process & efficiency audit include:

1. Increased labor productivity
   - Reduction of overtime
   - Reduced maintenance backlog
   - Reduction in paperwork
2. Increased equipment availability
   - Minimize downtime
   - Prolong useful life of equipment
3. Reduced inventory costs
   - Minimize obsolete and excess inventory
   - Optimize inventory levels

work process

Our philosophy is simple; we look at the basics first. Work Process Flow, Preventive Maintenance Optimization, Planning and Scheduling, and Inventory Management. We identify strengths and weaknesses through our on-site evaluation and offer suggestions for improvement through analysis and reporting.

PHASE I – Customer Needs Assessment

In this phase, our Maintenance Professional will conduct a question and answer session via telephone with the appointed project manager at your company or organization.  Through the conversation, the Maintenance Professional will help determine the areas that might need special focus and identify what you will need to have ready upon the site visit.

PHASE II – On Site Evaluation

A Maintenance Professional specializing in process-improvement and CMMS will visit your sight for 2 – 3 days.  During the visit, plant/facility personnel will be interviewed at all levels (director, managers, supervisors, technicians, clerical staff, IT personnel etc.). The average time per employee or group is 30 to 60 minutes and entire group interviews may also be necessary. Depending on findings, some key people are re-interviewed. This whole interview process could take 8 to 12 hours.

Standard Areas of Investigation:

Maintenance Work Process Flow

Work Process Flow is reviewed from start to finish. Our professional will sit down with different teams of personnel at your facility in order to get key feedback regarding the current process.   Shop/plant floor visit will help uncover areas that are unproductive, where delays are wasting time, and recommend improvements.

Typically maintenance organizations use 80-90% of their time on unplanned jobs and 10-20% on planned (preventive included) maintenance. Our professionals can help you reverse those numbers and cut down on the amount of “emergencies” your technicians deal with daily.

Preventive Maintenance Optimization

Your PM program will be reviewed, keeping critical assets in mind. We provide guidelines to help optimize your Preventive Maintenance frequency – either increasing it, or decreasing it (saving you money either way). We also review your Preventive Maintenance tasks and provide guidelines to optimize those.

Depending on your workforce and current state of affairs, this Preventive Maintenance Optimization alone can help save 20% or more in your Preventive Maintenance expenditures.

Planning and Scheduling

The Planning and Scheduling review goes hand-in-hand with your Work Process Flow review. The type of activities identified and corrected with this process are unnecessary travel, lack of parts and tools information on work orders, and lack of instructions etc. Upon completion of this phase, a typical work order (unless it is true emergency) is not dispatched until it is properly planned.

We have found that most facilities have little or no planning and scheduling processes in place. Instituting meaningful practices will turn your facility from a reactive mode to a proactive mode.

Inventory Management

Review of your inventory control program identifies obsolete and excess inventory establishing guidelines to help you turn your inventory into positive revenue.  We will also give you key solutions to better work with your suppliers to help you save even more money and gain critical work space.  Reorder points (ROP) will be reviewed with suggestions on how to help reduce money tied up in your inventory dollars.

Our evaluation, when successfully followed, can help shave 10-30% off of your annual inventory dollars.

CMMS (Current or Future technology)

Facilities without Current CMMS

Facilities that are contemplating the addition of CMMS will receive a detailed report with professional recommendations about the correct CMMS system required for improved facility optimization. It will also outline the specific steps required for successful implementation, and will present important information about CMMS planning strategy - specialized to your facility.

Facilities with Current CMMS

Reviewing your current CMMS has two primary goals: 
1) to determine how to maximize the utilization of your current CMMS 
2) to establish changes or upgrades you might want to consider for your CMMS.

One of our recent studies shows – up to 94% of companies don’t use CMMS to its full capacity. Our professionals will identify key areas where improvements can be made to boost your usage and efficiency.

PHASE III – Analysis and Report Development

Once the on-site evaluation is complete, our team then spends 2-3 days off-site going over the data and producing our report.  Discoveries will be reviewed in detail and additional phone interviews will be conducted if necessary.  After analysis, a report will be developed with final recommendations.

PHASE IV - Report Presentation

Phase IV includes delivery of a hard copy and electronic report.  The Maintenance Professional will review the results of the audit with your team members including recommended solutions for improving the efficiency of your maintenance program.  Review of the audit is conducted remotely by phone or internet presentation.  As part of this presentation the presenter will welcome questions and encourage a discussion of the results and report.

deliverables

1. Comprehensive written report with recommendations including potential benefits and savings
2. Professional consultation reviewing audit and report

 

Contact Us for a Free Consultation or Quote on Your Maintenance Efficiency & Process Audit Needs.