Efficient Factory

 ”If it ain’t broke don’t fix it”

 That phrase leads me to remember (if you’re old enough)  the Fram Oil filter commercials of the late 70’s and early 80s’. I just happened to find it on YouTube. This one’s from 1981.

So many people in remember the campaign because it was a good effective message with the tag line “you can pay me now, or you can pay me later”

Maintenance is an indirect cost that’s easy to ignore, until it’s too late and then it really costs you. There is a lot of noise about “total cost of ownership”. But it’s a tough sell in getting the culture of companies to accept it. That Fram Filter Commercial is effective as an example of preventative maintenance. Those small costs will always help to avoid the big costs .

For machine tools or critical production equipment, maintenance and downtime are the most expensive costs incurred. Predictive maintenance is growing in importance because it can be really cost effective. Once a company pays for service on a broken machine once, they really know what the pain feels like. The cost of the technician, the parts and especially the lost reveue and profit from lost production, all add up to a hefty bill. Being able to predict when maintenance is nedded takes a lot of uncertainty out of the equation – the killer of profitability.

These machines are increasing complexity. A technician has to be a mechanic, an electrician, and an IT expert. And they’re getting older. Most of the skilled technicians are in their 40’s and 50’s. You’ve heard of the lack of skilled workers – It’s going to get ominous as these older technicians retire with their knowledge.

The most promising solution is to automate maintenance. Today’s machine-to-machine technology is integrating sensors and IT is making this happen. 

Remember:

“If it ain’t broke don’t fix it” is not only bad grammar – it’s also not a strategy.