solution in place, the operation has been able to move from a break-fix maintenance model to a more preventative approach. Technicians now log maintenance reports directly into the system as they work, so there is less risk of a job being forgotten or entered incorrectly. As well as minimizing mistakes, this also helps to improve traceability—helping with audits, inspections and regulatory compliance.

“We have a strict workflow now that governs all planned maintenance,” adds Bowers. “Each job starts out with a Maximo work order—and you need an order number to get spare parts. This makes it much easier for us to keep track of inventory and ensure that the right parts are used for the right jobs.” Since the deployment, Bowers has noted a 10 percent increase in the amount of preventative maintenance being done and a corresponding 10 percent reduction in actual breakdowns.

“You’ve definitely got an idea whose time has come,” says John Boville, market segment manager for automation supplier Schneider Electric, with U.S. headquarters in Palatine, Ill. “You’re dealing with a mind shift here. I don’t think people really understand what’s at stake when a machine stops running. We are talking about big, big benefits. Instead of fixing something after you have a catastrophic failure, have a system that’s smart enough to tell where to go to avoid the breakdown in the first place.”

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