Sometimes, we tend to undermine the simplest things that would hurt our business. These leaks and damages often being neglected simply because the damages are deemed “too small”, and often we tend to react when the damage is significant. Leaks in the pipes, underperforming machines, or mismatch utilities and tools could hamper production and severely damage machineries. The slowdown of output means less product created and sold which could lead to a loss of potential revenue. Another thing to be concerned is by letting the machines and utilities became too damaged for repair, where often the cost could reach almost as buying a new one.
Maintenance – the act of maintain or sustain the livelihood of the machines that are being utilized in the production process is being viewed as a crucial factor in the operation of plants or factories. We have talked to plant managers or factory directors on the subject, 75% believe that the maintenance of machines is a priority of theirs while 84% confirm that machine maintenance is a way to boost revenue.
It’s not only a cost-cutting measure, precise and effective maintenance is an investment for company’s future.
A power plant or turbine needs a constant maintenance to avoid sudden breakdown, or worse – accidents. Also, a well-maintained factory or plant could maintain its optimal stability for a longer time. These are the benefits that you would create if you have done maintenance in a constant and precise conduct. So, why do we seem to neglect maintenance?
Shell Lubricants conducted a survey to 350 of Power sector staff in 7 countries, including Indonesia in early 2018. From the survey, 44% of the respondents admitted that maintenance is not prioritized until equipment breaks down. Some of the reasons as to why maintenance may not be prioritized by some business players;
- 48% did not realize that effective lubrications can help lower maintenance costs.
- 66% admitted that there’s knowledge gap and/or expertise in handling equipment breakdowns.
- 83% agreed that staffs need more training from the experts
72% respondent stated that unreliable equipment has led to unexpected costs – which is the least of a business need. Based on the survey by Shell Lubricants, 84% of the interviewees believe that effective equipment maintenance can generate savings.
A study by Zinda Law Group that has experienced in consulting cases of plant accidents has found that lack of maintenance is often the number one cause of accidents.
Another study by IMPEL, has described some accidents including the fire outbreak in a recycling plant in France, an explosion because of voltage dip in Germany, and rupture of an oxygen pipeline often began with supervisors and management of the site neglecting it’s a small problem that snowballed into a crucial or even devastating problem.
To overcome this, we need to start paying more attention to our machines and utilities. Initially, always use trusted products such as good lubricants to maintain your machines for a longer time. Choosing good products could buy you time if you don’t have the resource or manpower to perform routine and precise maintenance because lubricants are helping to maintain your machines performances day to day.
Maintenance is not an easy thing to do, especially when internal management and staffs are occupied with their main task in running the factory. Our data shows that 40% breakdowns is being caused by ineffective lubrication – a part of maintenance process. That scenario may explain why 48% of plant managers has stated that external / third-party support will improve maintenance. Moreover, 79% respondents state that lubricant provider that could share expertise in this particular context will be very helpful.
To conclude, maintenance is an important thing to do.
It could hinder unexpected expenses, maintain the lifespan of the machines and also a factor in generating revenue for the company. It doesn’t need to be done by your own team, if there’s too much going on and you can’t handle it, you can always contact a third-party to oversee maintenance in your factory.