Improving Safety with a Computerized Maintenance Management System

A CMMS provides better asset management, streamlined risk assessments, and improved emergency preparedness

Published: Wednesday, August 16, 2023 - 11:02

In the quickly changing industrial landscape, firms continue to place a high premium on safety. Innovative approaches to improving industrial safety have been made possible by technological advancements. One particularly revolutionary option is computerized maintenance management system (CMMS) software. This article examines how CMMS software transforms safety procedures in industrial settings, providing instances of its effective application in the real world.

Proactive asset management and equipment monitoring

A well-implemented CMMS software serves as the foundation of asset management, transforming how important equipment and machinery are maintained and monitored. CMMS can detect possible equipment faults before they occur by using predictive maintenance algorithms and real-time sensor data integration. This proactive method reduces safety hazards associated with unexpected breakdowns, maintaining continual equipment reliability and protecting workers’ well-being.

Real-life example: A large manufacturing plant implemented a CMMS software system that integrated IoT sensors with their production equipment. The system monitored various performance indicators, such as temperature, vibration, and power consumption. By analyzing these data, the CMMS predicted a potential fault in a critical machine, prompting immediate maintenance. This early intervention prevented a possible equipment failure that could have resulted in a hazardous situation for the operators.

Streamlined risk assessment and hazard identification

Industrial managers may quickly and effectively detect any dangers by conducting thorough risk assessments with the help of CMMS software. Managers may scan historical occurrences and near-misses for trends and possible hazards by centralizing data about equipment conditions, maintenance history, and safety protocols. By implementing safety procedures and preventive measures, businesses can successfully reduce the likelihood of accidents and promote a safer work environment, thanks to this data-driven approach.

Real-life example: A chemical processing plant used CMMS software to analyze past safety incidents and equipment failures. By identifying recurring patterns, they realized that a particular type of valve frequently caused leaks, leading to hazardous chemical spills. The plant promptly replaced these valves and implemented more stringent inspection protocols, significantly reducing the risk of chemical spills and potential harm to workers.

Enhanced emergency preparedness and response

CMMS software is essential to making sure industrial facilities are equipped to deal with crises in a timely and efficient manner. During a crisis, a CMMS enables instant access to vital information by recording emergency protocols, contact details, and safety measures. Workers can lessen the incident’s effects and guarantee safety by acting quickly and according to the set safety procedures.

Real-life example: A large oil refinery employed CMMS software to enhance its emergency response procedures. When a fire broke out, the CMMS provided real-time updates to the designated emergency response team, enabling them to swiftly mobilize resources and execute the evacuation plan. Thanks to the prompt response, no injuries were reported, and the fire was contained before causing substantial damage.

Streamlined training and certification management

Administrating employee training and certifications is made easier by CMMS software in a sector where qualified workers are essential to safety. To make sure that workers continue to be suitably trained and prepared for their positions, the system automatically reminds users when their certifications need to be renewed. A CMMS promotes a culture of ongoing education and skill improvement, which makes the workplace safer.

Real-life example: A construction company implemented CMMS software to monitor employee certifications for operating heavy machinery. When an operator’s certification was due for renewal, the system alerted the HR department, which promptly arranged for the required training. This proactive approach ensured that only certified operators handled the machinery, reducing the risk of inexperienced personnel causing accidents.

Compliance and regulatory reporting made easier

Industrial groups are required by law to follow safety requirements. By creating detailed documentation required by regulatory agencies, CMMS software streamlines the process of compliance reporting. This not only ensures compliance with safety requirements but also streamlines the auditing process, reducing the possibility of fines and providing a safe working environment.

Real-life example: A pharmaceutical manufacturing company embraced CMMS software to comply with good manufacturing practices (GMP) regulations. The system generated regular reports on maintenance activities, equipment calibrations, and cleaning protocols, making it easier for the company to demonstrate compliance during regulatory inspections. This resulted in consistently passing audits, reinforcing the company’s commitment to maintaining the highest safety standards.

How CMMS software improves industrial safety

General Electric

General Electric (GE) is a global conglomerate with a diverse portfolio of businesses, including aviation, healthcare, and power generation. To enhance industrial safety across its various operations, GE implemented CMMS software to monitor and maintain critical equipment.

In GE’s aviation division, CMMS software is integrated with sensor-equipped aircraft engines. This allows real-time monitoring of engine performance, fuel efficiency, and wear and tear. The data collected from these sensors provides valuable insights into potential issues, enabling predictive maintenance. As a result, GE’s aviation division improved aircraft safety, reduced unplanned downtime, and saved millions in maintenance costs.

Procter & Gamble

Procter & Gamble (P&G), a multinational consumer goods company, focuses on producing a wide range of household products. To ensure the safety of its manufacturing facilities and workforce, P&G adopted CMMS software for efficient asset management and maintenance.

P&G used CMMS software to centralize maintenance data from its numerous production lines. By analyzing historical maintenance records and equipment performance, the company identified areas prone to safety risks and implemented a preventive maintenance strategy to address potential hazards promptly. This led to a notable decline in equipment-related incidents, ensuring the safety of P&G employees while maximizing production efficiency.

ExxonMobil

ExxonMobil is one of the world’s largest publicly traded multinational oil and gas corporations. Safety is of paramount importance in its industry, and ExxonMobil leveraged CMMS software to elevate its safety standards.

ExxonMobil integrated a CMMS with its refinery operations and critical safety systems. The CMMS collected data from various sensors installed throughout the facility, including pressure, temperature, and gas-detection sensors. The software analyzed the data in real time and alerted operators and maintenance teams in case of abnormal readings, potential leaks, or safety breaches. This proactive approach significantly reduced the risk of accidents and improved emergency response capabilities, ensuring the safety of workers and surrounding communities.

Conclusion

These real-life examples illustrate how companies like GE, P&G, ExxonMobil, and others have successfully leveraged CMMS software to enhance industrial safety. By integrating a CMMS into their operations, these companies have achieved better asset management, streamlined risk assessments, and improved emergency preparedness. As the adoption of CMMS technology continues to grow across industries, we can expect even more organizations to prioritize safety and sustainability, making industrial environments safer places for workers and communities alike.

About The Author

Lindsey Walker

Lindsey Walker is the marketing manager for NEXGEN, a Sacramento, California-based industry leader in designing advanced computerized maintenance management systems and asset management software tools for utilities, facilities, public works, manufacturing, and fleet industries. In her free time, Lindsey enjoys traveling and reading, which allows her to gain new perspectives and inspiration for her work. She is committed to creating content that connects well with her readers, enhancing their digital experiences.