Maintaining the seamless operation of your equipment is an ongoing difficulty in the ever-changing realm of industrial operations. Are you poised to overcome these maintenance challenges confidently? Companies in Advanced Technology Services (ATS) are here to assist with creative ideas that directly handle typical maintenance concerns. Supported by astute data, we will investigate the difficulties in industrial maintenance and show how ATS firms are changing things with sensible, workable solutions. Let’s get right in and explore how you could improve your operations to maintain flawless running conditions!
1. Overcoming unplanned downtime
Unplanned downtime might cost money. According to Aberdeen Group, it reportedly costs manufacturers between $100,000 and $200,000 every hour. According to the 2023 Data Center Survey of the Uptime Institute, 60% of data centers experience yearly unexpected downtime.
ATS firms reduce unwanted downtime by using condition monitoring and predictive maintenance systems. For its industrial operations, General Electric (GE), for example, uses predictive analytics to track equipment status and forecast breakdowns before they start. GE proactively handles maintenance using sensors and machine learning techniques, reducing unplanned downtime and failures.
2. Controlling high maintenance costs
High maintenance expenses might tax resources. With 70% of the estimated $960 billion spent on corrective activities instead of preventative measures, the Global Maintenance Management Market study projects that by 2025, maintenance expenditures will reach $960 billion.
ATS firms streamline maintenance plans using data-driven insights. One example is Siemens, employing its digital twin technology to replicate maintenance requirements and equipment performance. Siemens saves a lot of money by projecting when maintenance is needed, as it helps extend the lifetime of equipment and minimizes pointless chores.
3. Enhanced spare parts control
Inadequate spare part control causes delays and more expenses. According to the National Association of Purchasing Managers, bad management may raise inventory costs by up to 25%.
ATS firms use cutting-edge inventory control systems as their solution. Honeywell, for instance, maintains exact spare part inventories using its sophisticated MRO management systems, guaranteeing timely availability and lowering procurement costs. This technique reduces delays and helps to stop expensive emergency orders.
4. Handling skill deficit
Finding and keeping qualified maintenance staff is becoming more complex. According to the Deloitte 2023 Global Manufacturing Report, 55% of businesses have maintenance tasks for which they need more personnel.
ATS businesses bring in seasoned personnel and provide tailored training courses. Rockwell Automation offers comprehensive training and certification programs for maintenance staff, helping close skill gaps and guarantee that teams are competent in contemporary maintenance methods.
5. Update aging tools
Older equipment may not fit modern systems and calls for more regular repairs. The U.S. Department of Energy reports that seventy percent of industrial facilities run equipment over ten years old.
ATS providers help with equipment modernizing and upgrading. For example, ABB provides retrofitting services to modernize outdated machinery with the newest technologies, improving performance and compatibility. This method combines modern technology with the usable life of current equipment to help extend both.
6. Managing excessive data
Interpreting and organizing vast amounts of maintenance data may be taxing. IDC forecasts a significant data management difficulty as industrial system-produced data will exceed 80 zettabytes by 2025.
ATS firms apply data management techniques and sophisticated analytics. For instance, IBM’s Maximo Asset Management system offers real-time data analytics and insights, enabling companies to make educated maintenance decisions based on accurate and timely information.
7. Giving Safety top importance
Activities related to maintenance might endanger Safety. According to the U.S. Bureau of Labor Statistics, industrial industries account for more than 200,000 occupational injuries yearly.
ATS firms stress safety procedures and thorough training as solutions. For instance, Caterpillar uses industry standards and comprehensive safety programs to incorporate Safety into its maintenance procedures, lowering the chance of mishaps and guaranteeing a better workplace.
8. Simplifying maintenance methodologies
Older maintenance methods might cause inefficiencies and higher expenses. According to a survey in Maintenance Technology magazine, half of businesses still employ antiquated methods that affect equipment dependability.
ATS firms apply modern maintenance techniques, including Total Productive Maintenance (TPM) and Reliability-Centered Maintenance (RCM). For example, SKF employs RCM to increase the dependability and effectiveness of maintenance procedures, improve the equipment’s operation, and lower maintenance expenses.
9. Getting around regulatory compliance
Following laws might be challenging. According to the Regulatory Compliance Institute, 15% or more of a company’s operating budget might go toward compliance expenses.
Through thorough maintenance programs, ATS businesses assist with regulatory compliance. For instance, Schneider Electric guarantees that maintenance procedures follow industry norms and guidelines and offers compliance consultancy to help companies avoid legal problems and fines.
10. Including new technologies
Combining new technology with current systems can prove challenging. Although 65% of industrial enterprises struggle with integration, the World Economic Forum notes that 72% invest in digital technology.
ATS firms specialize in technology integration, which includes cutting-edge technologies such as machine learning and IoT ( Internet of Things). For instance, Cisco ensures flawless integration with current systems by including IoT solutions in industrial maintenance procedures, improving equipment monitoring and performance. Explore how advanced fiber technology can elevate your operations and discover the future of maintenance with innovative solutions that drive efficiency and performance!
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