Maintenance management a defining factor in supply chain success
The challenges posed by globalization, e-business, and introduction of new technologies have placed the functional activities of supply chains at the top pedestal of many organizations. Enterprises are optimizing their supply chains to remain competitive in the global market place. Supply chain managers are increasingly embracing the philosophy of maintenance management to optimize production and operational value.
Supply chain facilities are employing numerous maintenance strategies and philosophies that have become a defining factor in successful, profitable, and competitive businesses. Many are utilizing a combination of several techniques to achieve company goals.
Maintenance management techniques of supply chain for better results
Stand-alone Reactive Maintenance
Reactive maintenance (RM), also known as corrective maintenance (CM) is performed on an asset or equipment only when the equipment encounters a problem or in the case of its failure. When this happens, maintenance staff repairs the asset to press it back into service. RM repairs are more common in facilities that do not employ a preventive maintenance or predictive maintenance procedures. Generally, supply chains that employ predictive or preventive maintenance plan witness decline in the need for corrective or reactive repairs.
In preventive maintenance (PM) supply chains carry regular maintenance tasks on equipment and machinery in order to prevent the occurrence of a failure. PM protects and extends the life of machinery. They are therefore crucial to asset management success. PM is scheduled and performed on a regular basis in order to prevent the sudden breakdown of machinery and ensure that the equipment are in working condition. PM also ensures timely replacements of critical parts and consumables, such as oil and lubricants so that they are changed regularly to optimize performance and productive value.
Predictive maintenance (PdM) is performed after the assessment of the condition of assets and equipment. The assessment data is analyzed to determine if maintenance is required. This method is considered to be cheap as compared to preventive maintenance as it allows maintenance staff to work on equipment only when the assessment study says it is necessary rather than on a defined schedule. PdM is also termed as condition-based maintenance or monitoring as it serves multiple purposes. Maintenance managers can also utilize asset inspections opportunity, such as infrared, vibration analysis and sound analysis to capture data and assess equipment condition.
Total Productive Maintenance (TPM)
Total Productive Maintenance can be called the health and fitness program for machinery. Its goals include reducing downtime, thereby increasing productivity, employee morale and job satisfaction. It ensures smooth productive running of the machinery and wards off the need for unscheduled emergency maintenances that reduce productive time.
TPM is the outcome of lean manufacturing initiatives that emphasize continuous process improvement and the need for collaboration of production and maintenance personnel to take overall responsibility for asset health. It blends the benefits of a proactive maintenance approach (Predictive and Preventive Maintenance) with the tenets of Total Quality Management (TQM).
Many reports state that there are some top companies such as Ford, Eastman Kodak, Dana Corp., Allen Bradley, Harley Davidson that have derived the benefits of implementing Total Productive Maintenance into their supply chain solutions.
Supply chain managers are always looking for a way to improve their operation and warehouse management. Maintenance management not only improves operation and warehouse management but has emerged as a defining factor in successful, profitable, and competitive businesses.