Understanding the top challenges faced by Maintenance Managers according to our 2022 Maintenance Manager Report
In order to gain a greater understanding and insight into the challenges faced by Maintenance Managers across the globe, we conducted an extensive report calling upon experts in the field of maintenance to share their knowledge and experience. The results of our report uncovered multiple challenges noted by professionals, providing the industry with valuable information on how maintenance operations can be tackled efficiently and effectively.
We have delved deeper into the key findings from our 2022 Maintenance Manager Report, exploring the common challenges respondents face and ways to overcome them. From the reliability of equipment to budget and resource constraints, we will investigate each finding in detail…
Key Findings
1. Reliability of equipment
What the data shows
The results from our report highlighted that 39.9% of participants noted that the reliability of equipment was the biggest challenge they faced as Maintenance Managers. In the context of maintenance management, reliability refers to the ability of equipment to perform its intended function in a manner that is safe and free from breakdowns and failures.
Problem
As assets continue to age and equipment starts to reach the end of its operational life expectancy, the quality and reliability of equipment will reduce. This often presents issues such as frequent breakdowns and incompatibility with modern technology or systems, leading to increased downtime and growing costs associated with replacing or maintaining older equipment.
Solution
To overcome this challenge, Maintenance Managers should look to establish an effective preventive maintenance program. By implementing a proactive approach to maintenance such as conducting regular inspections, prioritising maintenance activities and ensuring that equipment has been serviced correctly, Maintenance Managers are able to identify potential issues before they arise and turn into costly breakdowns.
2. Getting people to use CMMS properly
What the data shows
Noted as the second most common challenge facing Maintenance Managers in our 2022 report – at 36.7% – was the ability of personnel to properly understand and utilise CMMS systems.
Problem
Introducing a CMMS signifies a large change for many organizations, the sheer size and complexity of the system can make it daunting for employees to use without the correct training.
When employees are able to use a CMMS correctly, it unlocks the ability for maintenance teams to effectively carry out maintenance activities as the data included in the system is accurate and relevant. However, when CMMS training is insufficient or the expertise of a system begins to erode, Maintenance Managers are often left with the repercussions, such as incorrect or outdated data within the CMMS system.
Solution
In order to overcome this challenge, Maintenance Managers can implement various strategies to encourage employees to use the system correctly. For example, comprehensive training should be your first point of call when it comes to teaching your employees about using a CMMS.
You want your team to feel confident using the system and sharing their knowledge with others, to do this Maintenance Managers could run practical workshops or lead by example and show employees how they benefit from using the system.
Have a read of this case study in which we provided SAP navigation and familiarization training for an oil and gas client to see the benefits and deliverables that training like this will provide.
3. Budget/resources
What the data shows
Over the past few years, budgets and resources have presented a persistent challenge for Maintenance Managers across the globe, confirmed by the results of our report showing that 34.7% of respondents viewed budget/resources as the biggest challenge faced.
Problem
At the scrutiny of harsh budget cuts, Maintenance Managers are often placed under pressure to deliver effective maintenance activities with a limited budget and resources. This is a difficult act to balance and can result in the decline of maintenance activities.
Solution
Instead of solely eliminating the campaign activities due to a lack of budget and increased costs, Maintenance Managers should spend time conducting a risk assessment to evaluate the potential consequences of reducing the activities.
It is crucial that Maintenance Managers understand the ramifications of neglecting these activities and determine the most effective approach to mitigate any adverse consequences.
4. Competency of team
What the data shows
According to our Maintenance Manager Report, team competency was recognized as the fourth largest challenge faced by respondents. Building and maintaining a competent and skilled workforce is essential for streamlining operations, reducing the risk of health and safety incidents and minimizing unnecessary downtime.
Problem
In some cases, maintenance professionals with numerous years of experience retain their knowledge and pass it on to newer professionals via word of mouth rather than keeping a written log of what they know. When these experienced professionals begin to retire and leave the field, their knowledge can sometimes leave with them, creating a skills shortage because information can’t be referred to in writing.
This skills gap makes it increasingly difficult for Maintenance Managers to seek out and hire highly skilled workers, highlighting the importance of investing in training and development programs.
Solution
Introducing a fit-for-purpose competency management framework to accompany any existing documentation and procedures can help to foster a culture of continuous learning while also building the confidence of team members to carry out their roles. Courses in field maintenance, field production operations or maintenance management would help to upskill your professionals by providing them with extensive hands-on asset management, maintenance, integrity, CMMS utilization and inventory management experience.
This approach to training and competency will help to retain and build upon the skills of the current workforce, in addition to attracting new talent to the company.
5. CMMS data quality
Problem
CMMS systems are powerful tools designed to streamline maintenance operations, manage inventory, aid asset management and provide essential data used to improve decision-making. However, many CMMS systems rely heavily upon the accuracy and regular maintenance of the data inputted by team members.
Ensuring the integrity and quality of the data throughout CMMS systems can be challenging due to a number of factors such as employees forgetting to input data or submitting incomplete information, causing gaps in data throughout the system.
Inconsistent data entry can also lead to issues surrounding duplications, leading Maintenance Managers to believe that they have more assets held in stock than are actually available. This can present serious problems for materials management teams who may have to resort to emergency purchasing to resolve the issue of missing or incorrect CMMS data.
Solution
To address this challenge, Maintenance Managers should look towards creating a clear set of guidelines on CMMS data entry, including topics such as product descriptions, data formats and essential fields.
Alongside this, training should be provided to those who frequently use the system, helping to standardise the approach towards data management. Utilising a master data build and optimization software such as Effio™ would significantly help with these tasks.
Download the full 2022 Maintenance Manager Report for insights from hundreds of Maintenance Managers across the world, alongside tips and valuable advice from our maintenance experts…