Predictive Maintenance

How predictive maintenance ERP can help business in cost reduction?


Machines are the lifeline of a manufacturing plant. Machines, if run at full capacity, ensure ‘on time and in full’ quality delivery of products. To ascertain that your machines run at optimum speed and time, scheduling their preventive and conditional monitoring is inevitable. It is because your plant productivity is dependent on the effective maintenance of your machines. Your maintenance professionals should be able to identify failures much in advance and lay steps to prevent them from happening. Machine engineers should be able to mitigate machine downtime and maximize the useful life of machines. 


What does your plant need?


Your plant needs a strong maintenance strategy to maintain the good health of machines. Your plant needs a predictive maintenance ERP system that helps in anticipating various significant machine breakdowns and failures. The best ERP system ascertains plant productivity and saves 10%-40% or more maintenance cost. It ensures asset availability, reliability, and traceability for parts and equipment to amplify the plant runtime. 

Moreover, the Internet of Things (IoT) also plays an important role in predictive maintenance. When used effectively in conjunction with right sensors, actuators, and devices, the engineer can easily determine the condition of in-service parts and predict exact maintenance (cleaning, lubricating, retightening or Inspection) and repairs to be performed. 

This is the time when machine maintenance should move from ‘mend-when-it-breaks’ to proactive maintenance

So, throw out the old-fashioned methods of machine maintenance and invest in developing condition monitoring software. Let’s have a look at how an ERP system is taking predictive maintenance to a new level.


How ERP takes predictive maintenance to the next level?


An ERP system gives real-time data analytics and forecasting abilities to machine engineers and operators to save as much as 40% repair cost. Successful installation of a condition monitoring software helps manufacturers with the following benefits.


Real-time equipment monitoring and reporting: Saves machine maintenance cost and production time


Through a combination of ERP system and IoT devices, a machine engineer can track the utilization of each part and all equipment. Based on the information collected, scheduling maintenance initiatives becomes easy. The condition monitoring software sets up the rule for collecting and processing information from sensors to make the data available in the form of instructions, recommendations, and maintenance alerts. It sends out error codes or signal of any type to help the engineer identify the breakdown easily and quickly. Using predictive maintenance or repair history of particular equipment along with real-time sensors, it predicts the pattern of failure and lays alternative steps for handling the repairs.  


Zero communication gaps between workers: Speeds up production runtime and save cost spent on product rejection.


The ERP System is easy to connect with mobile devices. It gives updates about the machines, equipment, spare parts, and materials in real-time. Every employee who is a part of the production chain is able to track all the activities at different stages. It gives cross-departmental insights and builds standard units of measurement with no room for guesswork.  

All the workers starting from the top floor, shop floor to remote machine technician can receive automatic machine maintenance alerts directly on their mobile devices. It gives clear recommendations divided department-wise to conduct proper machine maintenance at regular intervals of time. Doing this ensures that there is no fault in any part of the machine to produce a faulty product which might get rejected at the final stage. 

With effective ERP implementation, all the equipment and machines work in order and the end product is free from errors. And, therefore you see a significant cost reduction that previously used to occur due to quality rejection.


Improve plant productivity: Offers precision, accuracy, and promises zero wastage


ERP implementation if done right ensures that your plant runs at full capacity. It means that the OEE of your plant is between 90%-95% and there is zero delays in product delivery. There is no wastage of material and optimum use of Money, Manpower, Methods, and Machinery. This is the ideal case which is easily achievable with the help of a condition monitoring software.  Although there are other powerful technologies involved like AI, Robotics, etc., starting with an ERP system will save up to 40% cost you spend on machine maintenance and repair. It can boost your productivity let’s say from 33% to 65% or more. 


Predictive maintenance is beyond anticipating failures and repairs. It also identifies opportunities to improve and build your decision-making process better based on undeniable and actionable data. It helps in building a strong cost reduction strategy and lay steps for improving the plant capacity and customer satisfaction.