Maintenance management is an indispensable component for manufacturing companies, as it ensures the availability and efficiency of machines and systems. The correct planning and implementation of maintenance measures can reduce downtimes, lower production costs and extend the service life of systems. It also makes a decisive contribution to increasing operational reliability and optimizing production processes, which strengthens a company’s competitiveness in the long term.
Total Productive Maintenance (TPM) is a preventive maintenance approach that aims to maximize the efficiency and availability of machines by involving all employees – from management to operators – in maintenance.
Main aspects:
Increasing machine availability: TPM reduces unplanned downtime through regular inspections and preventive maintenance.
Employee involvement: All employees take on maintenance tasks, which promotes personal responsibility and relieves maintenance teams.
Prevention of errors and accidents: Machine breakdowns and accidents are reduced through training and regular maintenance.
Continuous improvement: Optimizing processes increases the effectiveness of the systems (OEE) and reduces losses.
Cost reduction: TPM reduces maintenance and downtime costs in the long term and improves product quality.
TPM increases efficiency, reduces costs and promotes employee responsibility, which increases machine availability and production quality in the long term.
Maintenance is of central importance in maintenance management in order to ensure the service life and functionality of systems.
There are different types of maintenance:
Benefits:
Production is closely linked to maintenance management, as the availability and performance of the machines ensure continuous production. Regular maintenance maximizes uptime and minimizes unplanned downtime. By coordinating maintenance measures with production planning, for example through preventive maintenance during scheduled breaks, production remains efficient. Condition monitoring and predictive maintenance make it possible to plan maintenance based on actual machine usage, which avoids breakdowns and extends the service life of the systems. This helps to control costs by reducing emergency repairs and using resources more efficiently. At the same time, regular maintenance ensures consistently high product quality and prevents rejects. In this way, maintenance management makes a significant contribution to the company’s competitiveness and profitability.
A risk analysis in the context of maintenance management serves to identify potential hazards and weak points that could impair the operational capability of machines and systems. The aim is to minimize the probability and impact of risks such as machine downtime, safety problems and high maintenance costs. Here are the most important aspects:
Identification of risks
Risk assessment
Risk mitigation and avoidance
Proactive maintenance
Documentation and communication
Cost-benefit analysis
Risk analysis for spare and wear parts
A well-conducted risk analysis in maintenance management helps to prevent production downtimes increase safety and extend the service life of machines. It is a central component of a proactive and strategic maintenance policy that both reduces costs and increases efficiency.
Spare parts stocking refers to the systematic storage of spare parts to ensure the operational readiness of machines and systems. It is about having the right spare parts in the right quantity and in the right place to minimize downtime. Effective spare parts stocking takes into account factors such as delivery times, storage costs, wear and tear on parts and the importance of the machine in question. Good organization and management of spare parts stocks can ensure significant cost savings and greater operational reliability.
More about spare parts managementParts lists play a central role in maintenance management as they provide a complete overview of all components and materials required for the maintenance, repair or replacement of machines and systems. They are an essential tool for planning and carrying out maintenance measures.
A precise and up-to-date parts list us an indispensable tool in maintenance management. It ensures efficient planning and implementation of maintenance measures, helps to control costs and guarantees the timely availability of spare parts. A well-maintained parts list therefore makes a decisive contribution to minimizing downtimes and increasing operational efficiency.
D&TS is happy to support you in setting up and maintainig your parts lists – especially in the SAP PM environment.
Contact us nowEquipment classification in maintenance management is a systematic process used to categorize all machines, equipment and tools in a manifacturing company according to specific criteria. This is crucial for optimizing maintenance strategies, increasing efficiency and maintaining an overview of the condition and requirements of the equipment.
A basic distinction is made between equipment classification in SAP in the PM (Plant Maintenance) and MM (Material Management) modules. In both modules, classification can be carried out according to ECLASS, for example, and this is intended to significantly improve maintenance processes.
Equipment classification is a crucial tool in the maintenance management of manufacturing companies in order to effectively prioritize and optimize maintenance measures. It helps to focus on critical machines, use resources efficiently and minimize production downtime and costs.
Classify your equipment with D&TS today.
Feel free to call us or simply send us your request by e-mail.
Sebastian Böttjer
Head of Sales & Project Management