How can you align your maintenance budget with your production goals?

Key objectives of the maintenance system are to observe the health condition of any tool or machine which can impact the production output, make necessary steps if there is any symptom of a potential future problem and to eliminate unexpected production breakdowns. Mathematically a best in class maintenance system will increase the mean time to failure and decrease the mean time to repair. As a result it will improve the machine availability. As the machine availability increases, production output can be increased and the production goals will be met. Building up a better maintenance system will require some capital resources and a budget at the beginning. But in long term it will bring more benefits in terms of efficiency and output.

It has always been a challenge to synchronize the maintenance cost with the production volumes. Mostly the Finance will reach out to the Ops. & Maitn. Team to generate savings on the cost & align with the production volumes. Maint. is an integral part of the operations & it ensure the smooth operations when the machines are required to operate at maximum efficiency, overall equipment effectiveness (OEE). To ensure & keep running the equipment / machines, companies have to invest on Total Productive Maintenance (TMP). In the start of the TPM implementation there might be a cost increase but eventually in a longer run one can get the return on the investment (ROI) & the cost of maint. operations will be reduced even then the budgeted cost.

Actually, Maintenance is a key member of any kind of Production facility, advancement and prevention of the Maintenance department is a strength of Production. Ease of doing by workman or accident free environment, efficient output, accurate and quality product, spare parts management, know how of machinery, reduction of dependency on skill, technological updates etc. these all are basic needs of the Production department. We cannot separate out both functions. For the budget, we have to think about "Low cost solutions". Decisions are always situation based.

From a World Class Operation Management (WCOM) perspective, a world class maintenance pyramid is used to visualize the level of maturity of Maintenancecin a company.c Using my own experience together with this assessment we are able to Evaluate spending, weigh benefits and drawbacks, analyze impact on production metrics, and establish clear measurement methods. Identify gaps for improvement, enabling realistic goals aligned with maintenance budget and production targets.

In my opinion, you need to understand what you are currently spending on maintenance. Look at the amount of money spent for spare-part, the cost of downtime, and the cost of preventive maintenance. This will give you a baseline for the cost of maintenance, then use pareto to focus on cost improvement projects

Actually, proactive maintenance surely will help align the maintenance budget with production goals. But thats not all, WCOM (World Class Operation Management) in particular world class maintenance tends to balance the different maintenance strategy for your assets. This also includes reactive maintenance (yes!).

Proactive equal to Predictive maintenance, before breakdown accure, we must identify what are the potential to contribute the breakdown or failure and also identify the risk (risk base) of the failurer.

Proactive approach not only gives planned out but it also helps in synchronization of inventory targets, resulting in effective & faster value realisation.

Tracking and monitoring your maintenance budget is crucial to ensure compliance and make necessary adjustments with flexibility as per production targets.

It is always a more productive and efficient approach to adopt a preventive and predictive maintenance program, then to wait for equipment to breakdown, before repairing. The unplanned breakdown will disrupts the production schedule and output. Proactive approach will be to have preventive and predictive program over breakdown maintenance.

Maintenance system will help to be on track It could be simple excel based or machine history card based or a new age digital comma based maintenance system The idea is to capture data properly to do trending and hence improvement A good maintenance system can help align maintenance schedule, frequency, resource with budget and production needs and thus create a win win Maintenance management system also streamlines system to ensure planned maintenance and hence lesser chances of breakdown and hence avoiding/minimising breakdown maintenance which are big chunk of cost in maintenance budget With proper maintenance system we can know what part to change and when ( near to life ) vs ashok changing without analysis

Maintenance management system involves several key steps. 1. Asset Inventory 2. Prioritization 3. Data-Driven Decisions 4. Preventive Maintenance Planning 5. Budget Allocation 6. Integration with Production Planning 7. Continuous Improvement

I think the budget for each asset should be constructed by identifying the required preventive maintenance, predictive maintenance, historical corrective repairs, and expected refurbishments. The cost-effective execution of maintenance requires that an organization follow structured work management business processes.

A good maintenance management system will need to include spare parts inventory system, conversion kits management system, equipment performance monitoring system and reporting system. The maintenance management system has to allow managers to view and monitor the equipment performance and triggers warning when the equipment are not performing.

There are many sophisticated maintenance systems, and there are very simple ones. If both are maintained, they work well. Even a few clipboard in the right place on the shop floor, and a regular maintenance walk through once a week would help a company get ahead of many maintenance issues.

Competency is the most important thing for maintenance management, train the people save the money. TPM, WCM such a proved methodologies for training and involvement.

These programs should cover the latest technologies, maintenance methodologies, and equipment-specific knowledge. The aim is to empower staff with the expertise needed to proactively address maintenance challenges, contributing to improved equipment reliability and better alignment with production goals

Strongly agree with this Trained staff will helpful for achieving goals and involvement in new updates will very help in problem solving

In my experience this is the most important action that can be utilized. No one spends more time with these machines than the operators and giving them a since of ownership for the maintenance of the machines is a powerful motivator.

O treinamento adequado capacita os membros da equipe a entenderem os processos, identificarem oportunidades de melhoria e agirem de maneira coordenada. Além disso, promover um ambiente de comunicação aberta e incentivar o desenvolvimento contínuo fortalece a capacidade da equipe de enfrentar desafios e atingir metas de produção mais ambiciosas.

Review and control budget is dynamic process , as the maintenance goals also are dynamic. Sometimes quality is the target which will reflect the budget in certain way ,, sometimes decrease the downtime is the target which means increase the cost ,sometimes the cost wise is the concern and so on , so always I keep the budget align with goals and objectives to get maximum achievement

Every maintenance system is not perfect from day one. The programmer and the end users have to work closely, monitor and system, gather real time feedback from the end user and improves on the maintenance system.

The maintenance budget must be revised for production capacity. Because, high production capacity is need closely maintenance activities. Closely period maintenance budget is different normal production capacity. Also, spare parts quantity determination is different production capacity. At the maintenance system. We must a analyze system like Pareto.

External support is important for the creating strategy, though it is also comsumes the budget. So, every organisations should define their own unique way with their engineers.

External support may increase one time budget but it will reduce maintenance budget for long term. Because external support team trained for different purposes and different ideas solve problem in easy manners

Fashion is the field that creates alot of carbon footprint on the production process from Fabric to Material the allocation of each element has impact on the environment,So sustainability & Changing the course of fashion in more natural process & the time & efforts are not paid,So hence the Consequences. If we dont take actions now before its too late to doom of the industry.