“A critical motor that powers the lathe machine failed today and halted production completely. So, what’s next?” If you are a production or maintenance manager in your manufacturing facility, it’s not surprising to keep hearing such or similar questions from your technicians. This is an all-too-common scenario where machines that work incessantly are bound to fail one day or lose their full potential over time if not taken proper care of.
No matter how much you have invested in a machine, if you don’t take time to maintain it properly, it’s bound to break down one day, leading to considerable production losses. Just like our body needs periodic checkups, machines that operate continuously need checkups or inspections to ensure all their parameters are working properly or need overhauling or replacement. Hence, periodic inspections have become part and parcel of a maintenance lifecycle, which in no way can be overlooked or simply postponed, costing you millions of dollars or putting our organization’s reputation at stake.
However, if you are still following traditional, paper-based checklists for your inspections, then it’s time to reconsider your decision. In this digitally connected world, manual-based methods no longer work – going digital is the only way for a transformative, forward-based equipment inspection. This is what our blog is all about – it throws light on the significance of equipment inspections, the typical workflow, and the right digital inspection solution that offers a hassle-free, and reliable inspection experience.
As discussed earlier, inspections are a mandatory component in an equipment life cycle for any asset-intensive industry.
By performing regular inspections, you tend to derive the following benefits:
Comprehending the inspection workflow is the key to appreciating the challenges and opportunities for enhancement. A typical inspection workflow starts from raising a work order to final archiving and analysis. Here is the step-by-step inspection process workflow:
Any inspection starts with the creation of a work order. In other words, the inspection of equipment is carried out against a work order that forms the basis for an inspection process. Based on the requirement to check the condition of machinery – a motor, pump, or lathe machine, a work order is generated by the maintenance manager. This work order specifies the following details:
Once the work order is raised, it is assigned to a qualified inspector or maintenance technician. He/she reviews the details of the work order, collects the required tools, and makes sure to comply with all the mandatory safety protocols.
The inspector makes a visit where the equipment is located and performs detailed inspection concerning each parameter as enlisted in the work order. This process typically involves the following process:
However, recording data using only pen and paper is fraught with errors, while using a digital solution instead makes this process easy, effortless, and error-free.
Once the inspection is completed successfully, the inspector collates all the information/findings. This includes entering handwritten notes into spreadsheets or maintenance software. However, manual, paper-based entries are always prone to several challenges that include:
To mitigate these challenges, transition to digital forms that eliminates paper, while enforcing high-level data transparency, accuracy, and accountability to the inspection process.
Supervisors or maintenance planners review the inspection reports to:
This is the last stage of the inspection process. In this stage, inspection records are stored for future reference, audits, and trend analysis. However, with paper-based systems, retrieving and analyzing historical data is cumbersome.
As discussed in the preceding section, manual processes are fraught with several challenges like inaccurate data entry, delayed reporting, lost information, poor collaboration and missed productivity. If your company is still struggling with these challenges, it’s time for your organization to revamp your existing manual methods to go digital at the earliest.
In this context, look for an intuitive, user-friendly, and cost-effective mobile digital solution like that offered by Propel Apps, a leading supply chain transformation company. This solution transforms routine inspections into a seamless digital experience, directly integrated with your work orders and maintenance workflows. In other words, this solution seamlessly integrates with your existing ERP system (Oracle or SAP), delivering real-time inspection data and custom workflows at your fingertips. To know more about this solution, schedule a free demo with us.
Eliminate errors with digital data collection for accurate readings and no missed checkpoints.
Complete rounds efficiently with guided workflows, offline access, and automated tasks.
Gain instant asset insights, spot issues early, and trigger maintenance fast.
To know how this solution can make a difference to your current inspection process, fostering a better inspection and maintenance culture, schedule a free demo with us.
Digital Inspections have become a necessity, rather than a luxury. Manual, paper-based processes have never been efficient – incorrect & inconsistent data entries, poor collaboration, and missed productivity. If your organization is still struggling with the above challenges, this is the right time to go digital.
A digital inspection solution offers several benefits including instant capture of data, real-time insights, and greater collaboration across your team. So, move forward and make the switch – say goodbye to paper and do your bit to save the environment.
