Affordable Computerized Maintenance Management

Solutions (CMMS)Gabi Miles

Hach Company

May 22, 2009

Why Have a Maintenance Strategy

• Helps to manage your time– Plan when you do jobs– Keep a record of what you do– Stay organized– Improved system reliability

• Helps you save money!– Reduce down time (fix before it breaks)– Meet regulatory compliance– Better inventory management– Increase the residual value of your equipment

Maintenance System Options

• Manage maintenance department manually

• Automate the management of the maintenance department

• Automate Asset Management and Maintenance

Manual MethodUses spreadsheets, 3x5 cards, paper calendars to

manage the maintenance schedule

•Pro:– Very easy to implement– Inexpensive

•Con:– Reduces likelihood of implementing a rigorous

maintenance schedule– Potential unscheduled down time increases costs– Paper work to manage – file, track, lose?– Summary reports are very difficult to do

Do Job 1Go to site 3

Some Potential CMMS ROIs*

• CMMS users gain productivity: ~28%

• Inventory reduction: ~18%

• Downtime reduction: ~20%

• Maintenance labor reduction: ~ 10% to 40%

• Energy cost savings: 5% to 10%

• Project Management efficiency increase: ~5%

• Increase equipment value for resale: ~10% to 20%

*various studies

Asset & Maintenance Management

A computer program with a wide range of capabilities for an organization’s maintenance operations.

•Pro:– A comprehensive tool with lots of features– Ideal for finance and asset managers

•Con: – Over 60% of implementations fail!– Typically require big changes – Costly ~ 50K+ to $4.5M– Complex systems: garbage in – garbage out

Example: DATASTREAM

Automate the Maintenance Department

A computerized maintenance management program for maintenance operations

•Pro:– Simplicity of features focused on the maintenance

department– Easy to setup, learn and use

•Con:– Not well suited for large organizations with complex

needs

Features of an Automated Solution

Designed for maintenance people Easy, cost effective maintenance scheduling

solution

Easy to use calendar

Tracks details that matter to maintenance

Provides instructions, equipment drawings and

pictures.

Stays with a familiar format and simple process

Provides maintenance and business information

It Should Work the Way You Do!

• You put your jobs on a calendar.

• You check them off when they are done.

• You record the work in the equipment card file...

Interactive, Color-coded Calendar

• A simple calendar easily manipulated • Flexible scheduling of preventative work orders• Track corrective work orders

Generate Work Orders

• Incorporate graphics, detailed instructions, manuals

• Print for all or just for specific workers

• Add as many details as you need

• Use portables for accuracy and flexibility

Document Your Work

• Document what you need to:

• Who• What• Parts used• Parts cost• Labor hours

Generate Maintenance and Business Reports

• Equipment History

• Top Ten List

• Open work orders

• Equipment list

• ???

Consider Ease of Set Up• Flexibility

• Security

• Link to SCADA

CMMS Options: What’s The Best Fit?

• Manage maintenance department manually

• Automate the management of the maintenance department

• Automate Asset Management and Maintenance

• Organizational needs– IT needs– Purchasing– Finance (asset mgmt)

• Comfort with computer systems

• Facility size

CMMS Options: What’s The Best Fit?

Water Information Management Solutions

Accurate, useful information

DashboardsDashboardsDashboardsDashboardsOther

•CMMS•USGS•EPA

Process data•SCADA / Historian•OPC, MODBUS, etc•Dataloggers•Operator logs

Lab Data•LIMS•Benchsheets•Commercial Lab

Field data•Portables•Log sheets

Third Party•Commercial Lab•Engineering Firms

Compliance & Verification Engine

Calculation Engine

Useable, Actionable, Reportable, Supportable

Secure Secure Central StorageCentral Storage

What Is Water Information Management?

Quickly generate & submit reports:

• built-in regulatory templates and wizards• built-in calculations

Helps you make immediate, informed decisions :

• streamlined reporting with intelligent alerts• enhanced graphing & charting tools

Using accurate data:

• automatically collected from (SCADA, LIMS, Commercial Lab, Portable devices, Excel, etc)

• manually entered (log sheets, etc)• downloaded from dataloggers