Objectives and Challenges
Our client was facing difficulties in digitizing their maintenance management processes and adopting Plex Systems as an effective tool for operations. The main goals of the project were:
- Implement the maintenance module in Plex Systems
- Optimize the creation and structuring of master data
- Develop efficient maintenance plans across six departments
Client Pain Points
Before our intervention, the team encountered several challenges that hindered the adoption of the new system and the shift toward digital processes:
- Resistance to change and low team engagement
- Difficulty making Plex Systems a truly useful tool for the maintenance team
- Need to transition from paper-based checklists to a digital format
- Requirement to minimize technicians’ screen time, allowing them to focus on shop floor tasks
- Proper configuration of Plex Systems to meet the needs of the maintenance function
Implemented Solution
To overcome these challenges, we designed and executed a series of solutions focused on digital transformation and enhanced maintenance management:
- Effective master data configuration, reducing screen time for the team
- Creation and scheduling of maintenance plans for six departments
- Training for supervisors, planners, and technicians on service order creation and management
- Daily shift log monitoring to track adoption progress
- Adjustment and ongoing monitoring of overhead crane inspections to ensure OSHA compliance
Roadblocks
Throughout the implementation, we had to overcome two major obstacles:
- Team engagement and resistance to change
- Identifying and resolving bugs within Plex Systems
Results Achieved
The implementation of the maintenance module in Plex Systems led to several key improvements:
- Proper functioning of recurring maintenance workflows
- Well-structured, easily accessible master data
- Improved management of maintenance records to meet OSHA and IATF compliance standards
Benefits
The digitization and structuring of maintenance processes delivered impactful results for the operation. Key benefits included:
- Systematized preventive inspection workflows
- Compliance with regulatory standards and customer requirements
- Solid foundation for digital maintenance management, providing greater control and operational efficiency
- Increased asset reliability through more accurate and accessible data
- Improved overall efficiency in maintenance management processes
