What sets MAINTelligence apart from other Asset Management software/CMMS’s?

A typical CMMS is more a  work order accounting system than a maintenance tool. Data is recorded in the CMMS for cost management, not to monitor or improve the reliability of the assets.

In designing MAINTelligence, the primary objective was to create a framework that incorporated both the CMMS aspects, (collecting costs and allocating resources) and reliability aspects.  Our customers made it apparent that there was demand for even more focus on the management of predictive and inspection based maintenance data, along with standard corrective and preventive maintenance work orders.

Many times the data in a CMMS can be collected but not acted upon. How does MAINTelligence overcome this problem?

MAINTelligence information is considerably more active and relevant to the condition of the asset than the information found in most CMMS databases. Inspection and lubrication work, which often comprise a high percentage of the total number of work orders in a CMMS, are handled more like predictive maintenance rounds. This greatly reduces the total number of work orders in the system, and makes it much easier for operators and lubrication technicians to both complete the actual task and to record the results of the inspections.

Another problem with CMMS tools – often predictive maintenance (PdM) recommendations for proactive maintenance never get turned into actual work orders. By integrating both asset basic care and predictive maintenance findings directly into the maintenance task schedule, work from PdM procedures is automatically generated, just like time or meter-based PM tasks. This allows maintenance planners to handle all tasks the same way, no matter what their origin. The significance of this is that maintenance schedules can automatically change based on the inspected or measured condition of the asset. And it doesn’t matter if MAINTelligence ISN’T acting as the CMMS – DMSI has interfaces to many other ERP and EAM systems that allow the user to trigger work orders automatically. 

What kind of impact can MAINTelligence have on overall plant and machinery reliability?  What kind of cost savings can a company expect from using MAINTelligence?

First of all, it’s important to understand that technology is only an enabler—technological solutions like MAINTelligence will not have any effect if the management and organizational cultural do not support reliability initiatives. Also, cost savings vary from operation to operation.  A couple of examples show the reliability improvements and cost savings that can be expected.

A refinery in Memphis, TN, reported the following results using MAINTelligence:

  • MTBF for rotating equipment improved from 42 months to 53 months
  • Reduced unplanned maintenance from 80% total maintenance expense to 15% total maintenance expense.
  • KPI on pumps has improved 61%
  • Documented savings $1-million dollars in maintenance cost/year.

At a pulp and paper mill in Louisiana in early 2004, mechanics’ inspections generate approximately 300 corrective work orders per year that have improved the overall stability of the manufacturing process.  By June 2005, the integrated reliability program was credited with a 20% ($30 per tonne) reduction in maintenance costs, this at time when paper mills had been shutting down due to high operating costs and oversupply. Plant personnel achieved this by embracing the integrated reliability concept and the culture of self-discipline that it implied.

What size of an operation does it take to justify purchasing MAINTelligence?

DMSI customers range from some of the world’s largest operations, such as the POSCO steel mills in Korea, to some relatively small operations like Aquarium of the Pacific in Long Beach, CA.  

Although DMSI spends a large proportion of time dealing with very large corporate installations, it could be argued that the small operations actually get more “bang for the buck” from MAINTelligence.  For a smaller operation, a single investment in MAINTelligence can be turned to many different uses – it can be used as a CMMS, a vibration analysis system, a lubrication analysis tool, an asset inspection system, an electric motor tracking system, and many other applications. Large operations tend to use MAINTelligence as a point-specific application – they acquire it to implement a specific program.

Can an organization start with just the Inspection/Basic Care handhelds?

Yes.  In fact, most of our customers start off using MAINTelligence just for Asset Basic Care. Often, it’s only after they have successfully implemented their operator rounds do they consider all of the other possibilities inherent in MAINTelligence.

We want to get a lubrication management program going, can MAINTelligence help?

Yes. As a development partner of ExxonMobil, it was one of the design requirements of MAINTelligence that it be able to manage lubrication programs. You can manage your lubricant inventories, your scheduled greasing and lubrication top-ups and set up condition-based lubricant change-outs, all using MAINTelligence and InspectCE / WorkCE handhelds.

We want to shift out of reactive and into proactive, how can MAINTelligence help?

Shifting out of a reactive maintenance approach into a more proactive one, takes a commitment by your organization and the people involved. It really is a culture change. It’s not something that happens in a vacuum. However, one class of tools – mobile computers – can do the most to facilitate the change.

Implementing a mobile inspection system such as InspectCE demonstrates a group commitment to a policy of proactive reliability.  Maintainers, operators, safety, health and environmental inspectors all use the same data collection system. When everyone involved sees the collected data used to trigger work before outages take place, it helps create an environment of trust where all the contributions to the plant’s overall reliability are valued and considered.

Therefore, the use of mobile computers facilitates comprehensive, accurate data collection and are an important first step in shifting out of a reactive mode and moving towards proactive reliability practices. .
Learn more about MAINTelligence InspectCE »

We have these vibration collectors, work with an oil lab, want to use MAINTelligence and still put some data into our process control system. Can we do that?

Yes - we have worked with our customers to develop interfaces for the maintenance modules of most major ERP systems. These interfaces are used to generate maintenance notifications / work requests and/or trigger preplanned work orders.

Don’t see your question here? Email us your question.

For support oriented issues, either log into Support Online or contact DMSI Support Group at support@desmaint.com.

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