MetalForge Industries, like many established manufacturing firms, faced significant challenges in managing its maintenance operations

This established metal industry company faced significant challenges in managing its maintenance operations. While they had implemented a Computerized Maintenance Management System (CMMS) in the past, its adoption was hindered by a complex and user-unfriendly interface. Technicians, the backbone of the maintenance team, found the system cumbersome and time-consuming, leading them to revert to traditional paper-based methods for recording tasks and maintenance processes.

This reliance on paper created several operational bottlenecks:

• Data Entry Bottleneck: The Maintenance Manager spent an average of 1-2 hours daily after work, manually transferring data from paper records into an Excel spreadsheet. This was a time-consuming and error-prone process, delaying data analysis and hindering proactive maintenance strategies.
• Delayed Response Times: Paper-based task assignments and notifications resulted in significant delays in responding to machine breakdowns and maintenance requests. This led to increased downtime, reduced production output, and higher operational costs.
• Lack of Real-Time Visibility: The absence of a centralized, real-time system made it difficult to track the progress of maintenance tasks, monitor equipment health, and identify recurring issues. This lack of transparency hindered effective decision-making and prevented proactive maintenance planning.
• Inefficient Communication: Communication between the Maintenance Manager and technicians was often delayed and fragmented, leading to misunderstandings and inefficiencies.
• Disgruntled Technicians: The technicians felt that the prior CMMS was a burden and not helpful. This caused a morale problem within the maintenance team.

Objective: The metal industry company sought a user-friendly and efficient CMMS solution that would:

• Improve technician adoption and streamline maintenance workflows.
• Reduce data entry burden and eliminate reliance on paper-based methods.
• Enable real-time monitoring and tracking of maintenance activities.
• Enhance communication and collaboration between the Maintenance Manager and technicians.
• Minimize machine downtime and optimize production efficiency.

Solution: Fabrico Implementation

The metal industry company chose Fabrico as their new CMMS solution, recognizing its intuitive interface, robust features, and mobile-first design. The implementation process involved the following key steps:

1. Needs Assessment and Customization: Fabrico's implementation team worked closely with the company to understand their specific maintenance requirements and tailor the system to their workflow. This included configuring asset hierarchies, defining maintenance schedules, and customizing notification settings.
2. User Training and Onboarding: Fabrico provided comprehensive training to the Maintenance Manager and technicians, ensuring they were comfortable using the system's features. The focus was on highlighting the system's ease of use and the benefits it would bring to their daily tasks.
3. Mobile-First Approach and Smartwatches: Recognizing the importance of mobility, the metal industry company embraced Fabrico's mobile app, enabling technicians to access and update information on the go. To further enhance responsiveness, the company invested in smartwatches for all technicians.
4. Data Migration and Integration: Existing asset data and maintenance records were seamlessly migrated from the previous CMMS to Fabrico. The system was also integrated with other relevant systems, such as production planning and inventory management.
5. Real-Time Monitoring and Reporting: Fabrico's dashboard provided the Maintenance Manager with real-time visibility into maintenance activities, equipment status, and key performance indicators (KPIs). This enabled proactive monitoring and data-driven decision-making.

Key Features Utilized:

• User-Friendly Interface: Fabrico's intuitive interface made it easy for technicians to navigate and use the system, leading to high adoption rates.
• Mobile App and Smart Notifications: The mobile app and smartwatch integration enabled technicians to receive instant notifications about new tasks and equipment issues, facilitating rapid response times.
• Automated Work Order Management: Fabrico streamlined the work order process, automating task assignments, tracking progress, and generating reports.
• Preventive Maintenance Scheduling: The system enabled the company to schedule preventive maintenance tasks based on equipment usage and time intervals, minimizing unexpected breakdowns.
• Asset Management: Fabrico provided a centralized repository for asset information, including maintenance history, specifications, and warranty details.
• Reporting and Analytics: The system generated comprehensive reports on maintenance activities, equipment performance, and KPIs, providing valuable insights for continuous improvement.

Results and Benefits:

The implementation of Fabrico yielded significant improvements in the company's maintenance operations:

• Increased Technician Adoption: The user-friendly interface and mobile app led to a dramatic increase in technician adoption. Technicians found the system easy to use and appreciated the real-time notifications and mobile access.
• Reduced Data Entry Burden: The elimination of paper-based records and automated data entry reduced the Maintenance Manager's data entry time from 1-2 hours daily to virtually zero.
• Improved Response Times: Smartwatch notifications and mobile access enabled technicians to respond to equipment issues and maintenance requests significantly faster, minimizing downtime.
• Enhanced Real-Time Visibility: The centralized dashboard provided the Maintenance Manager with real-time visibility into maintenance activities, equipment status, and KPIs, enabling proactive monitoring and data-driven decision-making.
• Streamlined Communication: Fabrico's communication features facilitated seamless collaboration between the Maintenance Manager and technicians, reducing misunderstandings and improving efficiency.
• Reduced Downtime and Increased Production Output: The proactive maintenance strategies and faster response times resulted in a significant reduction in machine downtime and a corresponding increase in production output.
• Improved Maintenance Efficiency: The overall efficiency of the maintenance team improved significantly, leading to reduced operational costs and increased profitability.
• Increased Technician Morale: The technicians are much happier with the new system, which has led to a boost in morale.
• Data Driven Decisions: The maintenance manager now is able to make informed, data driven decisions about maintenance.

Conclusion:

The successful implementation of Fabrico at this leading Metal Industry company demonstrates the transformative impact of a user-friendly and efficient CMMS solution. By addressing the challenges associated with the previous system and empowering technicians with mobile access and real-time notifications, Fabrico enabled the company to streamline its maintenance operations, reduce downtime, and improve overall efficiency. The investment in smartwatches proved to be a critical part of the success. The case study highlights the importance of choosing a CMMS solution that prioritizes user experience and aligns with the specific needs of the organization. Fabrico's robust features and mobile-first approach have enabled the company to achieve its maintenance goals and drive continuous improvement.