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Connected Worker Risk Assessments to Optimize Your Plant’s MRO Program

Whitepaper: Connected Worker Strategies to Embrace Social Distancing in the COVID-19 Era - Challenges and Opportunities
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No one needs to tell you that maintaining your facilities’ production units, lines and equipment costs a lot of money. And it’s probably not news to you that if you’re spending more than 5 percent of your asset’s value on maintaining that asset each year, you’re in a bad place. If that’s you, or even if it’s not, here’s something you will want to know: There’s a way to optimize your plant, cut your costs, increase production and ease the heat from ever-tightening profit margins. Not only that, adopting this strategy can help your front-line maintenance workers get more done faster, better, cheaper and safer.

It’s not magic. It’s simply taking advantage of digital transformation and the power of the Connected Worker. 

Keeping a plant up and running is a constant battle. It’s a battle a maintenance crew doesn’t always win. Numbers from Aberdeen Research reveal 82 percent of industrial and manufacturing facilities have experienced unscheduled shutdowns in the past three years. Those shutdowns come at a high price. Aberdeen estimates unplanned downtime can:

  • cost an industrial plant up to $260,000 an hour.
  • last an average of four hours.
  • prevent delivery of services to customers.
  • result in a loss of customer trust and future sales.

Deloitte, meanwhile, reports that poor maintenance strategies can reduce a company’s overall production capacity by as much as 20 percent. However, the research giant also says that only about 10 percent of industrial equipment ever actually wears out, meaning an overwhelming number of mechanical failures are totally avoidable.

Industrial plants are now realizing that run-to-fail maintenance programs simply don’t produce the cost savings they thought. If anything, they cost more than they save. They’re increasingly turning to preventative maintenance and digital transformation to remedy this. Digital transformation enables these plants to harness technology, such as mobile devices, smart glasses, AI/ML to improve and automate data collection and decision making (read our white paper here). Recent studies have shown that digital-first companies are 64 percent more likely to achieve their business goals than those that still use paper forms and binders to share mission-critical information. 

A Connected Worker Platform is one of the most versatile and powerful digital transformation innovations to optimize your plant. What is a Connected Worker Platform? Simply put, it enables industrial plants to empower their front-line workers with the information they need, when they need it and how they need it. 

A Connected Worker Platform eliminates slow, inefficient paper data collection and sharing, replacing it with real-time digital capture and distribution. Front-line worker can access step-by-step, visual and guided work instructions to get the jobs done faster, better, cheaper and safer. Front-line workers can connect with remote experts on demand via a two-way video call to deliver a “see what I see” experience. This digital process encourages greater communication between front-line workers, managers and back-office systems, such as SAP and IBM Maximo. Information silos disappear. Leaders have access to immediate data to make knowledgeable decisions. This helps them address maintenance issues before they become downtime-causing problems (view our video here).

Best-in-class Connected Worker Platforms provide the ability to connect and create conversations between people, machinery and work processes to improve people’s lives. An ideal Connected Maintenance Execution solution empowers the front-line worker with valuable information from ERP systems such as SAP. Front-line workers can access the equipment maintenance history, look up bills of materials hierarchy, availability of spare parts and then receive step by step, visual and guided work instructions on mobile or smart glasses to enable a “hands-free” operation to close jobs faster than a mere mobile app. These connected worker experiences are then turned into insights for executives, directors, managers and supervisors to reimagine their maintenance programs. Best-in-class Connected Maintenance Execution apps can transform a slow, reactive program into an efficient, proactive one that reduces downtime and increases production capacity.

This transformative maintenance automation solution is guided, intuitive and digitizes operational data. Users can seamlessly integrate SAP/IBM Maximo operational data with front-line worker work instructions, SOPs and more. Best-in-class platforms and pre-packaged apps are also agile and reconfigurable. This personalization allows users to rapidly respond to changing business and regulatory conditions. Finally, this easy-to-use platform empowers front-line workers and managers to collaborate and share data anywhere, at any time, enterprise-wide. 

One area where this can make a strong, positive impact on maintenance and operations is in work orders. Best-in-class Connected Worker Platforms support the creation of configurable digital SOPs, work instructions, risk assessments and checklists. Technicians and inspectors no longer perform operator rounds using paper forms, clumsy clipboards or heavy binders. Instead, managers and supervisors can quickly create digital work instructions, SOPs, and data capture forms with customizable fields to fit your unique operational requirements (read our whitepaper here).

Techs and inspectors are armed with mobile devices such as smartphones, tablets and smart glasses to complete these operations and visual and guided, step-by-step work instructions, SOPs and digital capture forms that can ingest the data in real time. Decision makers can follow the operator rounds and risk assessments via their own mobile device or through a desktop application. They’ll immediately know when an issue is found and can take corrective action much faster than through the old paper-based processes. Decision makers can address problems before they cause costly downtime, result in a safety issue or become a regulatory compliance concern (watch our on-demand webinar here).

Prioritize maintenance work orders based on the risk profile of all equipment throughout your plant:

  • Use risk information to prioritize push notifications and work orders
  • Rank issues based on problem severity, likelihood and duration, or the criteria of your choice
  • Embed risk and safety measures information in the work order’s safety plan section

Best-in-class Connected Worker Platforms  give you the power to reimagine and transform your maintenance, repair and operations program. It delivers the accurate and timely information you need to make knowledgeable decisions that positively impact your production and operations. It offers an efficient way to optimize your plant. To learn more about Innovapptive’s Connected Worker Platform, schedule a free demo today by calling 844-464-6668 or by clicking here.

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