Is it time to decommission your equipment?

Six ways to measure if your machine is still a productive part of the team.

01/26/2012


Excerpted from SMGlobal’s Maintenance Software Blog 

Many organizations have equipment that is several years old, maybe even several decades old. In fact there are quite a few that still use machines that are over a hundred years old! Just because equipment is old does not automatically mark it for replacement. There are several factors to consider when to finally bid goodbye to a piece of equipment.

  1. Can you still get spare parts? How much does it cost annually in spare parts to keep the equipment running? Your maintenance software can help by giving you detailed reports of spare parts use and costs over the year for different equipment. 
  2. Is better equipment available? Sometimes even if the equipment is still very functional it may make sense to upgrade and buy newer equipment because productivity is higher or maintenance costs are a lot less. Your maintenance software can give you an idea of the annual maintenance costs and downtime of the equipment you are considering for replacement.
  3. Is the equipment breaking down more frequently? Use maintenance software reports to get an idea of maintenance being done on the equipment over time. If you see trends that tell you that the equipment is breaking down more often or is needed a lot more maintenance it may be time to consider replacing it.
  4. Is the quality of the products being made by the equipment declining/ are you getting a lot of performance related complaints in spite of regular maintenance? This can be a sign of an equipment that needs replacement but can also be a sign of poor maintenance practices. Review who is doing the maintenance work and check work order feedback for signs that maintenance procedure are not being properly followed.
  5. Is most of your maintenance budget and time being spent on a few pieces of equipment? If you know that there are comparable equipment that need less maintenance that you can use instead, it may be time to seriously retire the “trouble makers” that are consuming most of your resources. Your maintenance software reports that can compare historical costs of different equipment can help you pinpoint the equipment to investigate.
  6. Do you still have the skills available to keep the equipment running in top condition? This is especially of importance when dealing with very old and complex equipment. You may only one or two craftspeople who know how to keep the equipment running. Unless you are able to implement a program of skills transfer to other personnel you may run the risk of not having the capability to fix the equipment when it breaks in future. If you have a lot of equipment you can identify such skills bottlenecks by looking at personnel usage reports in your maintenance software that show which personnel worked on which jobs over a period of time. If you see the same few people always called on to do maintenance on some of the equipment this may be a sign that you have a possible skills shortage for this equipment.


No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
Strategic outsourcing delivers efficiency; Sleeve bearing clearance; Causes of water hammer; Improve air quality; Maintenance safety; GAMS preview
World-class maintenance: The three keys to success - Deploy people, process and technology; 2016 Lubrication Guide; Why hydraulic systems get hot
Your leaks start here: Take a disciplined approach with your hydraulic system; U.S. presence at Hannover Messe a rousing success
Flexible offshore fire protection; Big Data's impact on operations; Bridging the skills gap; Identifying security risks
The digital oilfield: Utilizing Big Data can yield big savings; Virtualization a real solution; Tracking SIS performance
Getting to the bottom of subsea repairs: Older pipelines need more attention, and operators need a repair strategy; OTC preview; Offshore production difficult - and crucial
Applying network redundancy; Overcoming loop tuning challenges; PID control and networks
Putting COPS into context; Designing medium-voltage electrical systems; Planning and designing resilient, efficient data centers; The nine steps of designing generator fuel systems
Package boilers; Natural gas infrared heating; Thermal treasure; Standby generation; Natural gas supports green efforts

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
This article collection contains several articles on the vital role that compressed air plays in manufacturing plants.
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.
This article collection contains several articles on strategic maintenance and understanding all the parts of your plant.
click me