cmms best practices - maintenancecmms training resources 54% used the cmms vendor 21% used a 3rd...
TRANSCRIPT
CMMS Best Practices
CMMS Comparative Benchmarking SummaryOctober 2002 – May 2003
© Copyright 2003 NetexpressUSA Inc.All rights reserved.
Survey Sponsors
Reliabilityweb.comCmmscity.comMaintenanceBenchmarking.com634 ResponsesLargest CMMS Benchmark SurveyIndependent Source
3%Africa 5%Middle East 6%Far East 9%Europe
10%Australia/NZ/Pac Rim
7%Mexico/South America
52%USA/Canada
Participating Countries
6%under 10 employees
16%10000+ employees
24%1000-9999 employees
12%500-999 employees
20%100-499 employees
12%10-99 employees
Company Size
CMMS Market Breakdown
18% Datastream17% Maximo/MRO16% SAP PM
These 3 vendors own 51% of the CMMS Market
CMMS Market Breakdown
5% Indus4% MicroMain4% Developed In House CMMS3% JD Edwards/PeopleSoft2% Mincom2% Synergen197 others reported other vendors
Total number of work orders per month
4%More than 10K5%5000-100009%2500-5000
18%1000-250023%500-100033%100-5009%under 100
65% generate less than 1000 work orders per month
Only 35% of the market generates more than 1000 WO’s per month
Percentage of maintenance/repair work tracked in the CMMS
20%95%-100%45%75%-95%15%50%-75%20%Less than 50%
35% track less than 75% - This will reduce ROI from a CMMS
Percentage of maintenance spares inventory tracked in the CMMS
19%95%-100%
31%75%-95%
13%50%-75%
37%Less than 50%
50% track less than 50% of spares. This will also reduce ROI.
Rate the importance of the following functions
49%Key Performance Indicators52%Budget/Cost Analysis69%Spare Parts Management 65%Planning Function66% Scheduling Function 94% Work Order Management
Must HaveFunction
Only “Must Have” replies above 49% are included
Rate Your CMMS
11%Key Performance Indicators17%Budget/Cost Analysis27%Spare Parts Management 21%Planning Function25% Scheduling Function 45% Work Order Management
ExcellentFunction
49%52%69%65%66% 94%
Must Have
From Previous Slide
Implementation Resources
43% used the CMMS Vendor
21% used a 3rd Party Vendor
Opinion: CMMS Implementation is a highly specialized skill and outside of the core business of managing and operating a maintenance department. Using specialists who specialize in CMMS implementation may result in increased ROI
CMMS Training Resources
54% used the CMMS Vendor
21% used a 3rd Party Vendor
Opinion: CMMS Training is a highly specialized skill and outside of the core business of managing and operating a maintenance department. Using specialists who specialize in CMMS training may result in increased ROI
Acquiring and Supporting CMMS Software
46% spent more than $100,000 on the initial software licensesOnly 59% spend more than $10,000 annually on training, software upgradesOnly 40% offer formalized CMMS training for new maintenance employees
Note: Be sure and estimate a total cost of ownership for CMMS that includes upgrade hardware and software paths, and regular ongoing training. The software is not a silver bullet. Training is key.
CMMS Work Process Paradox
62% Changed Their Maintenance Work Process to Fit the CMMS66% Customized the CMMS to Fit the Work Process
Note: See what off the shelve CMMS functions can do before you customize. Change work process because it is inefficient or ineffective independent of CMMS
CMMS ROI or DOA?
60% Failed to generate an expected ROI on CMMS implementationOnly 21% consider their CMMS implementation a success
Opinion: ROI on CMMS is debatable as it is simply an enabling tool for maintenance, which is an enabling activity for production output. What is clear is that most companies have failed to generate theproductivity they sought as a result of implementing a CMMS
4 Critical Keys for Successful CMMS
Ease of use (79%)Top Management Support (71%)Low Learning Curve (63%)A Defined Maintenance Work Process (58%)
Comment: To generate an ROI you need to use a CMMS and use it correctly. It must be easy to learn and use and management must enforce its proper use.
What We say 5 Obstacles for CMMS Success
Lack of a CMMS Goals and Planned OutcomesLack of Integration Lack of a Comprehensive Maintenance Strategy Garbage Data Lack of Accountability
What survey participants say -
"We used an independent consultant for implementation. They proved to be invaluable.“"Every level of management, from the top down has to understand the value of a good CMMS & support it all the way."
What survey participants say -
"Keep the system simple with numbering and get input from all those that work with the system to make it intuitive to the user, not the engineers.“"Make a user the champion of implementation. Give this to someone with the desire to really learn."
What survey participants say -
"Avoid allowing the CMMS inventory and Procurement features to drive the maintenance requirements.“"Most important advice is to have a "death grip" on the scope of the project. Many organizations want to ask for the world but cannot afford to implement it effectively. Know your process first than specify what you need to accomplish it."
What others say -
There are great products in the CMMS software marketplace, from companies that have abundant experience, high levels of integrity, and who will work as hard as they can to help you be successful. Your challenge is to see through the fog of hype, massive amounts of information, and false claims, and find the vendor who is counting on your success, as opposed to your order.
Nicholas Phillippi, CEO of Application Resource Consulting Inc
What others say -
Ricky Smith of Life Cycle Engineering defines implementation as "having 100% of your assets loaded into your CMMS; 100% of all PMs written properly and installed in the CMMS; 100% of all name plate data, and all other elements to make the system provide accurate data, installed in your system." Source: Tracking Trends in CMMS/EAM Jack Smith, Senior Editor, Plant Engineering magazine May 1, 2003
What others say -
According to an updated study by ARC Advisory Group's Houghton LeRoy, "the majority of asset management market growth will come from application service providers (ASPs), web hosted solutions
What we say -
Most CMMS information is derived from vendors, trade publications and “analysts” who get paid by CMMS vendors to get press coverageUse groups like MESA and SMRP for independent informationUse Internet sites like Cmmscity.com, MT-Online.com, MaintenanceResources.com and Reliabilityweb.com Attend conferences like this one, IMC-2004 and CMMS-2005 the only independent CMMS Focus conference available.
What we say -
Track 100% of your work with CMMSTrack 100% of your spares and repair inventory with CMMS Use CMMS for Planning & SchedulingUse CMMS for BudgetingUse CMMS for Tracking Cost
What we say -
Understand and document your work processSelect an implementation vendor/partner that understands your work processDo not customize unless it is mandatoryTrain everyone involved on an ongoing basis
What we say -
Get absolute management supportTraining will make a system “easy to use”Use specialists for implementation and specialized report writingKeep your hardware and software updated
What We say -
Seek automated solutions PDA’sBar CodingRFIPaperless
Full CMMS Survey Available
CMMS Best Practices Survey is available at Cmmscity.com Email: [email protected]
MaintenanceConference.com
The International Maintenance Conference“Mastering The Maintenance Process”December - FloridaEAM “Enterprise Asset Management Forum”
RCM – “ Reliability Centered Maintenance Managers Forum”
Check the web at www.maintenanceconference.com for dates and locations.
Terrence O’Hanlonwww.Reliabilityweb.com