February 2024 Volume 6

MAINTENANCE

Leveraging ERPs for Maintenance: Benefits & Best Practices By Angela Gibian, CAE

Enterprise Resource Planning (ERP) systems have revolutionized various aspects of business operations, and the forging industry is no exception. ERPs have found extensive use in maintenance within the manufacturing sector. This technology has been used to streamline processes, reduce downtime, and enhance efficiency. Streamlined Operations: ERPs enable companies to coordinate maintenance activities seamlessly with other aspects of the business, such as inventory management, production planning, and procurement. This integration means that maintenance is scheduled at the most opportune times, reducing production downtime, and optimizing resource allocation. Real-Time Data: ERPs provide access to real-time data, allowing maintenance teams to monitor equipment health and performance continuously. This ensures timely intervention in case of issues, reducing the risk of unplanned downtime. Maintenance personnel can also analyze historical data to identify trends and potential problems before they escalate. Inventory Management: Efficient inventory management is also important for maintenance. ERPs help manufacturers keep track of spare parts and supplies needed for maintenance. This ensures that the right parts are available when required, minimizing delays in maintenance activities. Cost Control: ERPs enable manufacturers to monitor maintenance costs closely. By analyzing the data, they can make informed decisions about resource allocation and optimization. This cost control can result in significant savings over time. Asset Management: Maintaining a comprehensive record of equipment and assets is key for effective maintenance. ERPs facilitate asset tracking, helping manufacturers know when assets were purchased, their maintenance history, and their current condition. This information can aid in decision-making regarding equipment replacement or refurbishment. Challenges with the Implementation of ERPs Complex Implementation: Implementing an ERP system can be complicated and time-consuming. It requires careful planning, a financial investment, and the commitment of resources. Businesses must also ensure that their existing processes are compatible with the ERP system. Training and Adaptation: Employees must be trained to use the ERP system effectively. Resistance to change can be a hurdle, and some staff may be reluctant to adopt new technology. This necessitates a robust change management strategy.

Data Integration: Ensuring that the ERP system integrates seamlessly with existing data sources and legacy systems can be a technical challenge. This requires the expertise of IT professionals and a comprehensive data migration strategy. Security Concerns: The integration of sensitive maintenance data into an ERP system requires stringent security measures to protect it from cyber threats. Manufacturers must invest in robust cybersecurity to safeguard their data. Best Practices for Implementing ERPs Thorough Needs Assessment: Before selecting an ERP system, company leadership should conduct a comprehensive needs assessment to identify the specific requirements of their maintenance operations. This ensures that the chosen ERP system aligns with their goals. Proper Training: Adequate training for employees is crucial. Manufacturers should provide comprehensive training programs to ensure that employees are proficient in using the ERP system and understand its benefits. Change Management: Implementing an ERP system often involves a cultural shift within the organization. Manufacturers should invest in change management strategies to foster a culture of innovation and adaptation. Regular Maintenance of the ERP System: Just as equipment needs maintenance, so does the ERP system. Regular updates and maintenance of the software are essential to ensure it remains effective and secure. Data Analytics: Utilize the data collected by the ERP system to make informed decisions. Regularly analyze maintenance data to identify areas for improvement and cost-saving opportunities. The use of ERP systems for maintenance purposes has brought about positive changes for many companies in the forging industry. These systems offer a wide range of benefits. However, it is important to keep in mind that their implementation comes with a fair share of challenges. By following best practices, manufacturers can successfully integrate ERPs into their maintenance processes and in the end maximize their efficiency and productivity.

Angela Gibian, CAE, is the Deputy Chief Executive of the Forging Industry Association (FIA) and the Executive Director of the Forging Foundation (FIERF) She is also the Managing Editor of FIA Magazine. She can be reached by email at angela@ forging.org or by phone at 216-781-6260.

FIA MAGAZINE | FEBRUARY 2024 26