Urgent need to Implement a Machine Breakdown Tracking System

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Machine Breakdown Tracking System for Mr. Akira’s Automotive Factory

This machine breakdown tracking system case study examines the advantages of installing RipplesCMMS in Mr. Akira’s (plant manager) automotive component factory situated in Tumkur, Bengaluru, India. The system tracks and analyzes machine downtime trends, leading to increased efficiency, reduced costs, and promoting preventive maintenance practices.

Current Problems:

  • Unrecorded Downtime: Manual tracking of machine breakdowns is likely inefficient and susceptible to errors.
  • Limited Visibility: The absence of centralized data makes it difficult to identify trends, prioritize repairs, and allocate resources effectively.
  • Reactive Maintenance: Repairs likely occur only after breakdowns, resulting in unplanned production stoppages and potential product quality issues.

Benefits of machine breakdown monitoring system

  • Enhanced Data Acquisition: The machine downtime system is automatically capture machine downtime data, including duration, cause (5Ys), and time of repair.
  • Advanced Analytics: The system generates reports and visualizations to pinpoint recurring problems, prioritize maintenance needs, and predict potential breakdowns.
  • Proactive Maintenance: Scheduled maintenance is be based on real-time data, minimizing downtime and extending machine lifespans.
  • Boosted Productivity: By minimizing downtime, the CMMS significantly improved overall production output.
  • Cost Reductions: The system helped avoid expensive repairs and production delays, leading to significant cost savings.
  • Improved Decision-Making: Data-driven insights empowered Mr. Akira and his abnormality manager to make informed decisions regarding maintenance schedules, resource allocation, and machine investments.

Factors that influenced in selecting RipplesCMMS

  • System Selection: A multitude of machine breakdown solutions are on the market, with features ranging from basic data collection to advanced analytics. Mr. Akira considered factors such as ease of deployment, scalability, non interference with existing systems, value add such as bin tracking, temperature humidity, acceleration and ePaper integration.
  • User Training: Factory personnel wanted an easy-to-use solution, which needed less training on using the system to enter data, generate reports, and interpret the analytics.

Return on Investment (ROI):

The ROI of an RipplesCMMS has to be substantial. Reduced downtime, improved maintenance practices, and increased productivity have led to significant cost savings over time. The system also helps identify opportunities for process optimization, further using MTBF and MTBR, enhancing efficiency and profitability.

Conclusion:

Deploying a Machine Breakdown Tracking System offered a compelling solution for Mr. Akira’s automotive component factory. By gaining real-time insights into machine performance, Mr. Akira makes data-driven decisions to optimize production, reduce costs, and ensure long-term success.

 

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Industry 4.0
Duleep Sahadevan - Founder and director at Ripples. Bringing nearly 7 years of expertise in understand and building technology solutions for Industry 4.0