10 best practices for reducing
maintenance costs in the manufacturing industry
Maintenance costs account for a significant proportion of expenditure in the manufacturing industry. Yet it is possible to significantly reduce them while improving equipment efficiency and reliability. By applying proven practices and leveraging appropriate tools such as our CMMS Guide Ti, you can maximize productivity, extend the life of your equipment and optimize your processes.
These strategies, when implemented consistently, can transform your maintenance management into a true performance lever.
Here are 10 best practices to help you control your maintenance costs and optimize your operations:
1. Implement preventive maintenance
Plan regular inspections and maintenance to prevent breakdowns. This reduces costly downtime and extends equipment life.
2. Adopt a CMMS (Computerized Maintenance Management System)
CMMS software helps you centralize maintenance data, better plan interventions, and reduce costs by avoiding unplanned repairs and optimizing inventory management.
3. Analyze data to anticipate breakdowns
Collect data via sensors or IoT systems to practice condition-based or predictive maintenance, reducing the costs associated with emergency interventions.
4. Optimize spare parts management
Maintaining an optimized stock of critical parts prevents delays in repairs, while avoiding overstocking unused parts that tie up capital.
5. Regular technician training
Qualified technicians reduce repair times and improve the efficiency of interventions, which in turn reduces costs linked to human error.
6. Standardize maintenance procedures
Set up clear, standardized processes for every intervention. This reduces errors, speeds up interventions and optimizes resources.
7. Working with reliable suppliers
Establishing good relationships with quality suppliers ensures reliable parts and services, reducing breakdowns due to faulty equipment or components.
8. Evaluate and prioritize critical equipment
Identify the equipment whose failure would have the greatest financial or operational impact, and focus your maintenance efforts on it to minimize the costs associated with production downtime.
9. Reduce downtime with optimized planning
Rigorous scheduling limits production interruptions and ensures that technicians and parts are available at the right time.
10. Monitor key performance indicators (KPIs)
Monitor KPIs such as MTBF (mean time between failures) and MTTR (mean time to repair) to continuously evaluate and adjust your maintenance processes.
The result?
Not only do these practices reduce direct maintenance costs, they also transform your operations. By improving the productivity and reliability of your equipment, while minimizing downtime, you maximize performance and reduce operational risks. Thanks to optimized management and a proactive approach, you’ll achieve a sustainable reduction in expenditure while boosting your company’s competitiveness.
With Guide Ti, we support you in this process, giving you the tools you need to achieve concrete, measurable results.