7 Signs It’s Time To Hire a Manufacturing Maintenance Consultant

Plant maintenance can easily trend into routine. It’s simple enough to manage the day’s work orders in your CMMS and go through the motions, occasionally reprioritizing tasks to ensure everything runs smoothly. While consistency can be an asset in manufacturing operations, when it gives way to complacency, issues emerge. An important question also arises: When’s the last time you audited or evaluated your maintenance operations?

Even companies that regularly evaluate the efficacy of their maintenance approach can benefit from an occasional third-party review. Bringing in a manufacturing maintenance consultant is a valuable way to validate your maintenance efforts — and ensure they remain effective. Here are seven signs that it might be advantageous to bring in a consultant:

1. Your maintenance expenses steadily climb without a corresponding improvement in equipment reliability. This could be a sign of inefficient practices or a lack of preventive maintenance, either of which leads to more frequent repairs and higher overall costs. An outside consultant can bring in an objective perspective to assess priorities and guide resolutions.
2. Unscheduled equipment failure is disrupting your production flow and causing excessive downtime. Downtime means lost production and revenue. A consultant can help identify equipment weaknesses and implement preventive measures to minimize disruptions.
3. You primarily rely on reactive maintenance, fixing problems only after they occur. A reactive approach leads to unnecessary downtime and higher repair costs. A consultant can help develop a preventive maintenance plan to address equipment issues before they become critical failures.
4. Your current maintenance staff lacks the expertise to handle complex equipment or emerging technologies. The knowledge and skill sets required for modern manufacturing maintenance is constantly evolving. A consultant can bridge these knowledge gaps through training. They can also recommend hiring additional specialists.
5. Recurring safety incidents, related to equipment malfunction or inadequate maintenance procedures, are unresolved. Safety is paramount in any manufacturing operation. A consultant can identify and minimize risks to improve safety.
6. You’ve lacked the capacity or expertise to effectively integrate new predictive maintenance technologies like vibration analysis or infrared thermography. New technologies offer valuable insights into equipment health. A consultant can help you choose the right technologies and develop a plan for successful implementation.
7. You anticipate future growth will strain your current maintenance capabilities. Growth is exciting, but it also puts a strain on existing systems. A consultant can help you scale your maintenance program to meet the demands of future expansion. This is particularly useful if you’re diversifying or moving into new areas of production.

Hiring a manufacturing maintenance consultant is a strategic investment, and it can yield significant benefits. A consultant can help you streamline processes, reduce costs, improve uptime, and ensure the safety of your workforce. Taking this step demonstrates a commitment to continuous improvement and positions your manufacturing facility to grow faster and stronger in any sector.