Wednesday, November 25, 2009

CMMS and you...

ProTeus V Enterprise (click-on logo)
After 30-plus years in some type of maintenance role, I find it very interesting how the whole PM system has grown and yet has a long way to go. It seems that many companies, either large or small, still do not see the importance of a strong Maintenance Program to protect their assets ...and that includes their people and the environment. Some of the reasons I have read about (or people that I have had conversations with: Maintenance Managers, Facility Managers, and top Executive opinion) are the most common reasons cited to explain this - a lack of sufficient resources. For me, that is just an excuse for not understanding the cause and effect of, not doing. What ever happened to, "if there is a will there is a way" ?

Let’s just talk about ENERGY and HVAC and the effects and consequences, when not maintained. The approach to maintenance with respect to HVAC systems is particularly troubling, given the role that HVAC systems play in today’s facilities. HVAC systems in typical commercial buildings are responsible for more than 40 percent of total energy use. Keeping HVAC systems running properly and at peak efficiency is the first step in managing facility energy use. Take a facility that houses critical equipment that must maintain a certain temperature and humidity. Temperatures and humidity levels that fall outside of this range can lead to interruption in services and even costly system failures. Sometimes the difference between keeping a business running and having to shut down is nothing more than having a proper HVAC maintenance plan in place and performing the required tasks. It has been said that a well maintained HVAC system will use at least 15 to 20 percent less energy than those systems that are not maintained. Not only do you cut energy usage, but other things to consider would be Safety of personnel, Environmental impact (if you have a release of gases), down-time, and the cost of a major rebuild.

Now-days, with all the talk about Green and Energy, why not have a Maintenance Management System in place? Or, if you do have a Maintenance Management System, how are you using it? With all the Energy cost savings plans that are in place and because of the economic crunch that everyone is going through, is now the time to take the opportunity to look at what you are doing with your resources ...and how better to redirect your efforts for cost savings? Whether it be an Audit of your Maintenance System, an Energy Audit using an outside source (that by the way is free in most states), contact your energy provider for the details. The key to all of this is a strong CMMS, by strong I mean having a good data base with asset information, PM tasks and schedule, vendor and parts list, critical equipment backup information, the list could go on and on... Which gets back to the first comment that I made, PM systems have grown over the past 30 years, but they still have a long way to go. Not only do CMMS companies need to grow with the times, but you as an owner of a CMMS package, you need to unlock the potential that you have at your disposal. The number of companies that have a CMMS use about 30 to 40 percent of what is available to them. In the long-run, the effort that is taken will pay for its self by reducing down-time, costly repairs and time wasted (of the recourses you already have).

What this all boils down to is, how well you manage your assets.  And that will effect the Energy we use, the Environment, and the all-important "Bottom Line".  

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Why do I need CMMS?

Why do I need CMMS?  After all, we seem to be getting along very well without CMMS far as I can tell. We replace a motor now and then, we lose some production some time, because of a break-down, or we wait a week to get parts. The maintenance budget has been exceeded by 10% to 20% the last few years - this year it looks like it will be around 30% to 40%.  We had a few major breakdowns and a lot of over-time hours, as maintenance had to work a few days around the clock, plus the parts had to be rushed-in from over-seas. Now that I am starting to think about it, I have noticed a lot more contractors on-site the last 6 months and we have no major projects going on.

Just now, as I am thinking about this... the Plant Superintendent came into my office and is telling me that we missed a major shipment to our Number-One customer and we will not be able to fill the order for a week. A few months back, we missed a shipment to this same customer and because of this missed shipment they pulled their contract. As it turns out, without this contract we will need to let half the work-force go and if we cannot land another major contract, we will have to shut the doors.

I bet a lot of you who are reading this have lived it ...or have heard it before. I will be honest, CMMS is not the cure all but it dose help to avoid a lot of the pain.

• Embarrassment.
• Budget Overruns.
• Loss of Revenue.
• Lay Offs.
• Plant Closure.

Benefits from a CMMS:
• Improve Maintenance Productivity.
• Improve Machine Quality.
• Reduce Down Time.
• Monitor and Improve Employee Productivity.
• Have Critical Parts on Hand.
• Reduce Outside Contract Work.
• Monitor/Control Maintenance Costs.
• Increase Overall Productivity and Profits.

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ISO 9000 & ProTeus V Enterprise (ISO audits)...

ISO 9000 and Audits:  These are some of the key points that an ISO Auditor will look for during an Audit.

• Identify equipment (process/building/utilities/support services) that need PM to achieve conformity to product requirements.
• Determine and define the methods of PM (usually detailed by manufacturer of equip. in user manuals).
• Determine and define frequencies of PM (usually detailed by manufacturer of equip. in user manuals).
• Provide evidence (records) that PM's were done per schedule and method.
• Calibration requirements.
• Location.
• Tracking Number.
• Calibration requirements.
• Calibration interval with justification for the interval.
• Calibration Procedure.
• Calibration History.
• Calibration Due.

The standard clearly calls-out for a documented procedure for preventive maintenance. I have found that using process manuals (which contain all the needed procedures and forms, ie work instructions, daily records, preventive maintenance schedule, etc.) lends to keeping things nice and tidy in "ProTeus" and readily available for employees, management and auditors.  Maintaining assets in top operating condition is vital to meet production and service commitments. The ProTeus family of solutions has the following benefits -  designed-in, with the manufacturing industry in mind:

• Improving asset life – Overall Equipment Effectiveness (OEE).
• Process and action documentation for ISO compliance.
• Minimizing downtime.
MRO spare parts inventory control.
• Educated asset decisions.

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Discuss the possibilities with our staff?  

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Plugfest 2009 (BAS connectivity to ProTeus V)

On October 13-14, 2009 Eagle Technology, Inc. participated in BACnet PlugFest 2009 in Atlanta, Ga. Eagle Technology successfully tested its ProTeus Alarm Interface (PAI) with current and planned Building Automation Systems (from 12 vendors), including:

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Company profile, in brief...

We the employees of Eagle Technology are committed to providing world-class service and best-practice solutions for our customers. We offer measurable long-term value to all our users (partners and re-sellers) through our "ProTeus V Enterprise" software line. Founded in 1986, Eagle Technology, Inc. is a leading developer of Computerized Maintenance Management Systems (CMMS) and Enterprise Asset Management (EAM). ProTeus improves efficiency by helping facility and manufacturing maintenance operations to run smoothly, with minimal downtime any oganization. "ProTeus" (pro-Tee-us) provides for full-integration with intelligent buildings (BAS), and our solutions support LEED and Green standards. Over 3,000 maintenance professionals rely on "ProTeus" for its simplicity, reliability, scalability, and poly-lingual capabilities!  We VALUE your business!
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Eagle Technology CHICAGO (Sales Office)
Chicago, Illinois, U.S.A.
+1-262-725-3590 TEL
+1-262-244-0346 FAX
1-800-388-3268 Toll Free (Tech Support) 

The CHICAGO Sales Office was established in 2005.  Territory: Illinois, Wisconsin, Iowa, Indiana, Ohio, Minnesota, Michigan, Missouri (parts of Canada, Europe, and Latino America).  Languages spoken: Français, Español, Deutsch, Italiano, & Português.