We implemented a Computerized Maintenance Management System (CMMS) at AEDC used to document all maintenance actions and to provide information supporting data-based maintenance decisions. This involved procuring an off-the-shelf CMMS (Synergen product) that we transitioned into routine use in support of AEDC’s overall maintenance program.

Our Approach/Solution – Teams composed of subject matter experts first conducted research and developed reports addressing topics such as mean time to failure, mean time to repair, and annual maintenance cost. We then designed and implemented data input and collection processes to provide the required output reports. This information was made available to all maintenance personnel – craft, engineering, and management. We developed and implemented asset hierarchies within the CMMS and are currently populating it with equipment historical data.

All maintenance actions are documented on work orders within the CMMS. The work orders contain all pertinent maintenance information such as failure modes, repair/PM actions taken, materials utilized, and time and labor details. During implementation of CMMS we strongly emphasized planning and scheduling, and increased the ratio of planners/schedulers to other workers from approximately 2% to 5%.

Results and Benefits – All maintenance actions are now documented in a CMMS, and the resulting data are routinely used in maintenance decisions such as repair or replace, increase/decrease preventive maintenance intervals, and long-range planning activities. Overall productivity has increased by 14%, plant downtime has decreased from 12% to less than 5%, and total maintenance costs have been reduced by more than 10% while sustaining test facility availability above 90%. In addition, the CMMS has facilitated development of a multi-skilled workforce.

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