The search for maximum maintenance efficiency
Tom’s strategy was working. Reactive maintenance was down 54% and after-hours call-ins were down 47%. But there was still plenty of room for improvement.
Preventive maintenance was still being scheduled based on old habits. A compressor would be checked every few weeks, even if it was operating perfectly. Oil changes relied on whether technicians thought the oil was good or bad. And inspections were still being done manually. The team was spending hours checking meter readings and logging data every week.
And while asset failure and firefighting were down, Tom knew tasks like these were costing his team time and money they could be using somewhere else. So he set out to cut them from the schedule.
There was just one problem—Tom didn’t have the information he needed to pinpoint those jobs or the tools to automate them. So he teamed up with Fiix’s integration partner Majik Systems to find a solution.
Saving $40,000 a year with condition-based maintenance
With the help of Fiix and Majik, Tom connected the facility’s PLCs to his CMMS. This gives him the power to collect real-time information about the condition of equipment. Now he can track vibration, temperature, or any other machine reading.
But this data would be next-to-useless without the link between Majik and Fiix. This connection allows asset data to flow into Tom’s CMMS without him lifting a finger. If a reading hits a certain threshold, a work order is created.
The best part is the integration was done remotely. And it took only two weeks from start to finish (with less than a day’s work for Tom and his team).
“We now have alarms that are tripped and warnings to operators that if action is not taken or maintenance isn’t contacted that it could shut them down,” says Tom. “The plant runs 24/7, but maintenance is only here Monday to Friday. So it’s very important that we’re capturing all this information… because when we see a change in the condition of an asset, we need to take action.”
The results have been immediate and significant. It’s been nine months since Tom put Majik in place and has already cut costs by $40,000 from decreasing breakdowns and shedding unnecessary jobs from his team’s to-do list. This is a 300% return on his original investment in the project.
We’ve seen old issues fall off. Things like motor pumps and bearings replacements. They’ve all decreased. And the value of connecting Fiix and Majik will only increase as Tom continues to find ways to optimize his maintenance schedule and help his company make smarter CapEx decisions.
Supplementing condition-based maintenance with predictive maintenance
Condition-based maintenance was a huge step forward for PCI. But Tom knew that the next leap for the maintenance team was to start taking more predictive measures. He wanted to get to a place where failures could be predicted before they were even close to occurring – Fiix’s Asset Risk Predictor was the answer.
Because the team was already tracking things like pump current and torque, thanks to their Majik integrations, feeding that data into Asset Risk Predictor just made sense.
The data being collected and pushed through Asset Risk Predictor lets them do a deeper dive into those alerts than a CMMS could allow. Now, things like premature pump failure or excessive seal wear can be avoided, production can remain smooth, and they can make educated decisions based on all the data flowing into their system.
“We’ve had great success so far,” says Tom. On the question of failures, he joked that, “Unfortunately, we haven’t had a failure yet, but we have seen some of that data trend upwards to a yellow alert.”