2015 Maintenance Study: Reducing energy consumption on the plant floor

Respondents to the Plant Engineering 2015 Maintenance Study identified six high-level findings impacting the manufacturing industries today. See findings and access full report.

05/19/2015


Respondents to the Plant Engineering 2015 Maintenance Study identified nine important high-level findings impacting the manufacturing industries today:

  1. Source: Plant Engineering 2015 Maintenance Study, CFE MediaMaintenance strategies: 85% of manufacturing plants follow a planned maintenance strategy; while 62% still follow a run-to-failure method and 51% use predictive maintenance (PdM) with analytical tools.

  2. Strategy advantages: Planned maintenance is most popular due to numerous factors, including improved safety (81%), decreased downtime (80%), better productivity levels (80%), and overall efficiencies (76%).

  3. Shutdown schedule: Specialized and standard production machinery and less automated systems are generally shutdown once each year for schedule maintenance, while conveyor and production line systems are shutdown twice a year, material handling equipment is shutdown quarterly, and packing systems are shutdown every other month.

  4. Maintenance support: More than half of survey respondents indicated that their facilities’ rotating equipment and plant automation systems receive more maintenance support than fluid power systems, material handling equipment, and internal electrical distribution systems.

  5. Outsourcing: On average, 17% of maintenance services within a facility are outsourced, with top reasons for outsourcing being lack of time/manpower to dedicate to maintenance (50%), lack of skills among current staff (45%), and the requirement of too many specialized skills for particular tasks (41%).

  6. Training: 62% of respondents indicated that their maintenance teams receive basic mechanical and electrical skills training. Other training received includes lubrication (55%), PdM (43%), and welding and fabricating (35%).

  7. Technologies: Top monitoring/managing technologies used for maintenance include computerized maintenance management systems (CMMS, 58%), in-house created spreadsheets and schedules (48%), and clipboards and paper records of rounds (42%).

  8. Unscheduled downtime: The most popular cause of unscheduled downtime within respondents’ facilities is aging equipment (45%), followed by operator error (20%) and lack of time to perform maintenance (14%).

  9. View of maintenance: 41% of survey respondents believe that maintenance as a whole is a cost center, but understand that they need to spend in order to keep equipment running. Another 39% disagree, saying maintenance is a profit center there they can deliver greater capacity to their facilities.

Access the full Plant Engineering 2015 Maintenance report with additional findings and insights.



Top Plant
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2017 Top Plant.
Product of the Year
The Product of the Year program recognizes products newly released in the manufacturing industries.
System Integrator of the Year
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
February 2018
2017 Product of the Year winners, retrofitting a press, IMTS and Hannover Messe preview, natural refrigerants, testing steam traps
March 2018
SCCR, 2018 Maintenance study, and VFDs in a washdown environment.
Jan/Feb 2018
Welding ergonomics, 2017 Salary Survey, and surge protection
April 2018
ROVs, rigs, and the real time; wellsite valve manifolds; AI on a chip; analytics use for pipelines
February 2018
Focus on power systems, process safety, electrical and power systems, edge computing in the oil & gas industry
December 2017
Product of the Year winners, Pattern recognition, Engineering analytics, Revitalize older pump installations
April 2018
Implementing a DCS, stepper motors, intelligent motion control, remote monitoring of irrigation systems
February 2018
Setting internal automation standards
December 2017
PID controllers, Solar-powered SCADA, Using 80 GHz radar sensors

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

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