Saving Costs & Mitigating Risks by Usage-based Preventive Maintenance

Updated: Jun 19

Usage-Based Preventive Maintenance - The Inexpensive Way to Preserve your Tooling


Preventive maintenance (PM) is maintenance that is regularly performed on tooling to reduce the likelihood of it failing. Even now, most companies use time-based preventive maintenance, an inaccurate and detrimental method leading to consistent over and under maintenance of tooling.


Basing your maintenance on set time periods creates a fundamental problem within your tooling supply chain. For example, Company A conducts regular PM every 2 months on their tooling. This method only allows for two possible outcomes:

  1. Some tooling will undergo PM too early (not enough shots/usage), there is no need to conduct the PM just yet and companies end up wasting precious production time and human resources.

  2. Or some tooling will undergo PM too late (after it exceeded the number of shots recommended from its last PM), the PM should have been conducted earlier and being late will cause our tooling to have a higher chance of early failure.






This means that companies are not able to ever perform PM exactly when it should be based on actual usage. This leads to unplanned downtimes in production and pushes back the delivery schedule, ultimately debilitating the supply chain. Unplanned maintenance costs three to nine times more than preventive maintenance and time-based maintenance is just a guessing game.

Automating data collection within the tooling supply chain will help companies move from a time-based to a usage-based PM system. Usage-based preventive maintenance measures exactly when tooling should be maintained based on actual cycle count and provide the following benefits:


  • Companies will be able to save valuable time by automating data collection and reducing the period spent on basic data collection and reporting by tooling engineers.

  • Companies will be able to save money by reducing the amount of corrective maintenance and eliminating unnecessary preventive work

  • Companies will save their important human resources by giving them more time to focus on complicated tasks such as optimizing the production schedule

Usage-based preventive maintenance is simple but effective. For example, the tooling engineer designs tooling and knows that it should be taken out and cleaned every 100,000 shots. Suppliers operate the tooling and immediately before it reaches 100,000 shots an alert will be sent to the system, where tooling engineers can see the alert and examine the tooling. They can then conduct the required maintenance based on the tooling’s needs. Sounds simple but in practice, many companies are still unable to do so as there is no live cycle count data available.

This makes it impossible to conduct proper usage-based preventive maintenance. Most companies still have no way of tracking the exact cycle count of their tooling and rely on the supplier to conduct routine time-based preventive maintenance, which is unreliable and not cost-efficient. Finding a simple solution which provides quick and accurate data about tooling usage will provide companies with key information, giving them the insights to improve their process. With more data and better understanding of everyday operations in the tooling supply chain, companies can:


  • Improve their tools’ health by ensuring that maintenance is being done correctly, according to toolmakers outline.

  • Track part quality of production, minimize risks of poor parts being produced, and stop the use of tooling in critical condition.

  • Reduce the number of unplanned downtimes by ensuring maintenance is aligned with the suppliers’ entire production schedule, so there is no disruption in flow.



The Solution

eMoldino has created a fully integrated end-to-end solution for companies to gain access to accurate, live data about their tooling’s usage. Both suppliers and OEMs can receive notices about when their tooling are about to reach the designated number of shot counts needed for every round of maintenance. Usage-based preventive maintenance will help companies reduce costs, increase productivity, and enhance their supply chain to get the highest yield possible.

Companies reduce costs by only conducting PM only when it is truly needed

Increase productivity by removing inefficiencies in the tooling supply chain

Get their highest yield of products by using the tooling to its maximum number of shots



Solution Adoption Scenarios:

Below there are 2 possible scenarios. Which one best fits your company’s current situation?

Scenario One:

You an interested in implementing eMoldino’s solution into your in-house operations.

In this scenario, there are 2 possible situations. Please choose which one best fits your company currently.

You have an existing preventive Maintenance system for your in-house production.

In this case, your preventive maintenance system is most likely done based on time. eMoldino’s tooling supply chain management system can be integrated with your existing PM system. Data will be collected by our devices and analyzed by our innovative software, then sent over to your current PM system. In your existing PM system a new alert protocol will need to be created for the alerts to appear in your system. With our expertise and consultation, we will make sure that our data alerts appear in your system and preventive maintenance can be done accurately, on schedule, and seamlessly to cause as little disruption to your supply chain as possible. Once created, our data will send your system alerts and you can create scheduled PM times with your tooling team. The maintenance managers can now organize their time more efficiently and know exactly when the best times to conduct PM is to actively avoid losing any valuable production time.

You have no preventive Maintenance system for your in-house production.

In this case, our end-to-end tooling supply chain management system can act as the central management system for all your tooling and preventive maintenance needs. Our system will collect the usage data (shot counts) of your tooling and PM periods will be set so that once a tooling is approaching the end of a PM period, an alert will be sent. This alert can then be accessed by the maintenance manager and production team to schedule a PM during a time that best suits the production schedule. Once the PM has been completed, maintenance managers can change the status of the alert to “completed” and all the history will be available for OEMs and procurement personnel to check at any time.


Scenario Two:

You are interested in implementing eMoldino’s solution into your external suppliers.

In this case, OEMs are seeking more visibility into their external tooling supply chain. Their priorities are to check if PM are properly being conducted on their tooling as external suppliers have promised. OEMs can go into eMoldino’s cloud system to check if all PM alerts are fulfilled, and if not, if there is a specific reason for the delay.


External suppliers can easily upload any maintenance report(s) which contain any relevant information about PM performed. Once uploaded, the supplier can change the corresponding PM to “completed” and OEMs have full access to see if their tooling is being taken care of or if there is a breakdown, what might have caused this tooling to break down.


eMoldino’s solution allows toolmakers to upload all the necessary and detailed information about the tooling they have created for companies. They can include detailed manuals on how to conduct proper maintenance, video tutorials, pictures of the tooling and more. All this information helps the supplier by making it easier to access the information in one system, making conducting PM quicker and easier.



Conclusion


With a solid plan for usage-based maintenance in place, you will get back every dollar you invest and more. By proactively identifying and resolving tooling failure issues before they occur and being able to schedule preventive maintenance that best fits your supply chains operations, you can extend the usage and life of your tooling and reduce the need for costly unplanned maintenance.

Your tooling will work harder for you, increasing their contribution to your revenue without unscheduled downtimes and less unexpected failures.

To learn how usage-based maintenance can be implemented in your company, please reserve a 30-minute consulting session with one of our experts.

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