The Proof is in the pudding

Process of Change

We closed our previous article with the words, ‘never stop moving forward’. But the question remains ‘Does It All Work?

As the saying goes, ‘the proof is in the pudding’, so let us take a look at several case studies of organizations who have moved from a Reactive mode of maintenance to Proactive maintenance and have achieved this by successfully implementing and operating an effective Maintenance Management System.

Case Studies

So the burning question, ‘Does it all really work?

We are going to have a look at two cases studies from different Industrial Clients. The first client was not running any preventive program and was only operating a Reactive system, while the second client was running a preventive system but was not happy with their success rate. The graphics below show their journeys over a period of 18 months after implementing and running an effective maintenance management system.

Client 1 Graph

This is the first client, a very large international client who was virtually operating only with a Breakdown/Reactive operation with a very small percentage of planned maintenance activities.

Process of Change

We closed our previous article with the words, ‘never stop moving forward. But the question remains ‘Does It All Work?

As the saying goes, ‘the proof is in the pudding’, so let us take a look at several case studies of organizations who have moved from a Reactive mode of maintenance to Proactive maintenance and have achieved this by successfully implementing and operating an effective Maintenance Management System.

Case Studies

So the burning question, ‘Does it all really work?

We are going to have a look at two cases studies from different Industrial Clients. The first client was not running any preventive program and was only operating a Reactive system, while the second client was running a preventive system but was not happy with their success rate. The graphics below show their journeys over a period of 18 months after implementing and running an effective maintenance management system.

Client 1 Graph

This is the first client, a very large international client who was virtually operating only with a Breakdown/Reactive operation with a very small percentage of planned maintenance activities.

This bar chart shows the actual monthly readings quite clearly.

We can see how the first 9 months or so we’re a bit erratic, with some very large breakdown spikes but as the system was bedded in and disciplines were introduced, we can see from the last 9 months significant reductions in those breakdown spikes and a much more stable situation starting to evolve.

This was all achieved by implementing a reputable CMMS and ensuring that it was used correctly.

Note on the right side that the hours saved were recorded at 3000 man-hours per month.

Client 2 Graph

This second client was a much smaller local industry client and although the graph is not as dramatic as the first one, the picture is very similar.

This client had been attempting to introduce a good maintenance management system by themselves and they did manage to achieve some limited success as their preventive readings started at just less than 30% with the trend line showing them at 41%.

As we can see they were successful in improving their preventive maintenance to a healthy 59% over the reported period.

This is not such a dramatic increase as the first client however for a small industrial operation that increase of 18% also represented a very significant increase in cost savings and production volumes with Breakdowns being reduced from 59% to 41%.

Client 2 Bar Chart

And here again, we can see from this bar chart a very similar picture to the first client. The first half of the reported period reflects an unstable situation with the second half showing a very settled picture.

Note on the right side that the hours saved were recorded at 320 man-hours per month.

Summary

Well, two case studies from different Industrial Clients.

One starts from a zero preventive base and the other starts from a not very effective preventive base and yet both clients achieve significant success and cost savings over a period of time.

Discipline, commitment, and passion for success are often key ingredients because the efficiency savings are there. They just need to be released.

Does it all work? The proof is in the pudding

For more information email us at info@strobe-al.co.za or visit www.strobe-al.co.za