Maintenance Process Automation for Asset Lifecycle Management with Zero CMMS

CLOUD-BASED MAINTENANCE MANAGEMENT SOFTWARE

Zero CMMS is a computerized maintenance management system designed for effective asset lifecycle management and delivered as a software service through wireless data networks. This comprehensive platform integrates various software modules for decision management, asset management, maintenance management, inventory management, procurement management, cost management, and document management, along with monitoring and system administration, providing users with a unified solution for all their maintenance needs.

DECISION MANAGEMENT

DECISION MAKERS

Zero CMMS addresses the challenges maintenance decision-makers face with complex number-based reports by integrating with Microsoft Power BI. This integration facilitates visual reporting and data analytics, making it easier to interpret data and gain insights, ultimately enhancing decision-making processes.

VISUAL REPORTING

Zero CMMS integrates seamlessly with Microsoft Power BI, allowing for dynamic reporting through real-time data visualizations and analytics. Dashboards can be customized dashboards according to specific customer needs, ensuring that insights are relevant and actionable as new data becomes available. This integration enhances decision-making and operational efficiency for maintenance management.

DATA ANALYTICS

Maintenance decision makers can analyze historical data to make informed decisions by viewing dashboards and visual reports in Power BI. Zero CMMS users need also a Microsoft Power BI Pro or Premium subscription. Notably, a user with a Microsoft 365 E5 subscription automatically receives a Power BI Pro license.

MACHINE LEARNING

Power BI Premium enables automated machine learning (AutoML) for developing binary prediction, classification, and regression models, which can be utilized to forecast machine failures. Power BI’s AutoML features provide an excellent entry point into machine learning.

PREDICTIVE MAINTENANCE

Predictive maintenance strategy helps organizations anticipate asset failures, significantly reducing unplanned downtime and preventing asset breakdowns. Machine condition data is collected from sensors and IoT devices. Data Analytics and Machine Learning are used to detect failure patterns, allowing maintenance before breakdowns. On average, predictive maintenance boosts productivity by 25%, decreases breakdowns by 70%, and lowers maintenance costs by 25%.

Zero CMMS mobile application can be used to start collecting machine condition data manually by reading meters and making measurements with portable measurement equipment on the factory floor or in the field. Additionally, it integrates with condition monitoring systems that utilize sensors and IoT devices for automatic data collection, ensuring comprehensive insights into equipment performance.

FIXED ASSET MANAGEMENT

ASSET MANAGERS

Fixed asset managers face challenges in gathering asset records as they are dispersed across various business management systems. Zero CMMS was created to centralize asset records in a single system, simplifying the process of finding all records in one location.

ASSET RECORDS

Zero CMMS enables the  creation of a single master record for each long-term tangible piece of property, plant, and equipment that a company maintains and uses in its operations to produce products and deliver services.

Asset master records consist of fixed asset acquisition information and location data, documents, recommended spare parts lists, technical data and information, instructions, digital twins, work orders, check objects, machine usage and condition data, list of replacement equipment, and timeline.

ASSET HIERARCHY

Zero CMMS allows for the creation of an asset hierarchy that outlines both the functional and physical locations of assets. This hierarchy can be visualized on maps and digital twins, making it easier for users to locate maintenance objects quickly and efficiently.

PREVENTIVE MAINTENANCE MANAGEMENT

PM WORK ORDERS

Preventive maintenance (PM) work order records include essential components such as the maintenance plan, allocated resources, scheduled tasks, and timeline. They also detail required materials and services, along with maintenance instructions, checklists, and any necessary work permits. This comprehensive documentation ensures that maintenance activities are well-organized and efficient.

MAINTENANCE PLANNING

Zero CMMS streamlines the process for maintenance planners by making it easier to develop preventive maintenance plans, organize tasks, and efficiently allocate resources. Additionally, it enables the effortless duplication and modification of existing preventive maintenance work orders for new machinery and equipment, thereby optimizing maintenance operations and boosting efficiency.

ROUTE WORK ORDERS

PM TASKS

Zero CMMS automates the creation of preventive maintenance (PM) tasks according to the service interval specified in the PM work order, which can be based on time or equipment usage. Each task includes essential work order details, document links, required materials, instructions, checklists, and work permits. PM task executors can manage materials, borrow tools, report hours worked, and document outcomes through reports and photographs, streamlining the maintenance process and enhancing accountability.

ROUTINE MAINTENANCE

Machine operators and other operations staff can be enabled to execute routine preventive maintenance tasks that require only fundamental level  maintenance knowledge, experience, and skills without the need for spare part replacement or equipment swapping.

CORRECTIVE MAINTENANCE MANAGEMENT

CM WORK ORDERS

Corrective maintenance (CM) work order records include the maintenance plan, schedule, allocated resources, and timeline, along with required materials and services, maintenance instructions, checklists, and any necessary work permits. CM work orders can be bundled for simultaneous execution, with each bundled task having its own resources, start dates, and due dates, ensuring efficient management of maintenance activities.

MAINTENANCE SUPERVISORS

Zero CMMS improves maintenance efficiency by automatically generating corrective maintenance (CM) work orders when urgent service requests, machine breakdowns, or incidents occur. This automation enables maintenance supervisors and service team leaders to respond quickly, ensuring prompt action in critical situations and reducing downtime.

SERVICE REQUESTS

Zero CMMS is capable of automatically creating Corrective Maintenance (CM) work orders in alignment with service level agreements (SLAs) set between operations and maintenance teams. The details from the service request are transferred to the work order, and the deadline is determined based on the SLA. Furthermore, service requesters are automatically notified upon the completion of the related task, promoting efficient communication and workflow management.

FAILURE NOTICES

Machine operators can use the Zero CMMS mobile app to report machine failures directly from the factory floor or in the field. This initiates the creation of a new corrective maintenance (CM) task. Zero CMMS automatically logs the repair duration, calculating the Mean Time To Repair (MTTR) for tracking and reporting purposes. It also automatically records the Mean Time Between Failures (MTBF), offering valuable insights into equipment performance.

HAZARDS & INCIDENTS

The Zero CMMS mobile app simplifies the process of reporting observed hazards and incidents. It automatically generates a new work order or lets users manually create one by copying the report details, thereby making the reporting process more efficient and improving safety management.

CM TASKS

Zero CMMS generates a CM task using the details and due date from the work order. This task includes all relevant work order information, document links, necessary materials and services, along with instructions, checklists, and work permits. CM task executors have the ability to issue materials and services, borrow tools and equipment, and log their working hours. They can also document the task by writing reports and taking photographs. Additionally, CM tasks offer the option to swap equipment with replacement units.

CONDITION-BASED MAINTENANCE

Zero CMMS enables the collection of machine condition data through both manual input and integration with automated monitoring systems. When machine conditions surpass predefined thresholds, the system automatically generates a work order to restore the machine to its optimal state, promoting efficient maintenance and operation. This functionality helps ensure that equipment remains in peak working condition.

INVENTORY MANAGEMENT

MATERIALS

Zero CMMS allows for the creation of a single master record for each inventory item stored in warehouses. These spare part and material records include essential information for procurement, such as physical shelf locations, manuals, receiving and shipping documents, and links to fixed assets where the spare parts and materials are used, and purchase order history. They also provide details about manufacturers, suppliers, and vendors, while the timeline tracks every event throughout the inventory item's lifecycle, ensuring comprehensive management and oversight.

Zero CMMS efficiently manages raw materials, supplies, and goods used in production or service delivery, including perishable items, by implementing a first-in, first-out (FIFO) system. It also allows for the management of unique items through serial numbers or other identifiers, ensuring accurate tracking and inventory control.

TOOLS & EQUIPMENT

Zero CMMS manages the inventory of tools and equipment similarly to spare parts and materials. These items can be issued for maintenance tasks and returned to the warehouse or scrapped once the tasks are completed, ensuring efficient tracking and utilization of resources.

Zero CMMS supports the borrowing and lending of tools and equipment, enabling warehouse management to track the location and accountability of valuable items. Each time tools and equipment are returned, they can be inspected, maintained, and repaired as needed. This tracking capability is particularly beneficial for maintenance service businesses that use tools and equipment at customer locations outside the factory, ensuring efficient management of resources in the field.

SERVICES

Zero CMMS enables the management of services in a manner akin to handling spare parts and materials, despite services not usually being classified as inventory items. Services can be assigned to work orders and returned if they are not provided as expected. As services are intangible, there is no requirement for physical counts or scrapping processes, and they do not affect the overall inventory value. This feature improves operational efficiency and accountability in the management of outsourced services.

RECEIVING

Zero CMMS allows warehouse management to create receiving work orders that include checklists for inspecting and verifying incoming shipments. If necessary, receiving documents can be scanned and uploaded to the system, linking them with the receiving work order, supplier, and purchase order before storing spare parts, materials, tools, and equipment in their designated physical locations. This process enhances accuracy and accountability in inventory management.

INVENTORY TRACKING

Zero CMMS simplifies the management of issuing, returning, and disposing of spare parts, materials, tools, and equipment, as well as facilitating their transfer between warehouses. Moreover, physical inventories can be efficiently conducted using barcodes, QR codes, or NFC codes with handheld devices or mobile apps.

SHIPPING

Zero CMMS enables warehouse management to generate shipping work orders and efficiently scan and upload shipping documents to both the work order and the receiving company. Although sales orders are generally not part of maintenance management systems like purchase orders, they can be created for customers who need them, thereby improving overall operational flexibility.

PROCUREMENT MANAGEMENT

PURCHASE REQUESTS

Purchase requests can be created manually or automatically by Zero CMMS. Purchase requests can be created when allocating spare parts, materials, or services to tasks, or when performing physical counts in the warehouse. Purchase requests are created automatically for items who have reorder point and acquisition lot size defined.

SHOPPING CART

Zero CMMS enables all purchase requests to be saved in the shopping cart. From there, they can be chosen and included in purchase orders, simplifying the procurement process and ensuring effective management of purchasing tasks.

PURCHASE ORDERS

Zero CMMS allows purchase managers to create purchase orders by selecting items from the shopping cart and adding them as purchase rows. They can also create purchase rows from scratch. Purchase order details are pulled from the company register, which maintains all company records, ensuring accurate and efficient procurement processes.

COMPANY REGISTER

Zero CMMS includes a comprehensive company register that contains the names and contact information of manufacturers, distributors, suppliers, vendors, customers, and other companies. Users can also attach documents to each company record, which enhances the management and accessibility of important information.

COST MANAGEMENT

LABOR COST

Zero CMMS enables maintenance planners, workers, and external contractors to log hours worked on tasks either in real-time or retroactively. Once maintenance managers approve these recorded hours, the hourly labor costs—defined for resource groups—are automatically integrated into the cost management module, streamlining cost tracking and management.

MATERIAL COST

Zero CMMS enables maintenance and warehouse teams, as well as maintenance personnel, to assign spare parts and materials to maintenance tasks or directly to maintenance objects. Material costs are automatically integrated into the cost management module, and the inventory management module calculates the average cost of an inventory item whenever new spare parts and materials are received, allocated, or discarded, ensuring precise cost tracking and management.

SERVICE COST

Zero CMMS allows services to be added to work orders and allocated to specific tasks or directly to maintenance objects. The costs associated with these services are determined by the latest purchase value, ensuring accurate cost tracking for maintenance activities.

OTHER COSTS

Zero CMMS enables managers to manually input both internal and external costs within the cost management module, allowing for allocation to specific tasks or maintenance objects. Furthermore, costs can be imported from external purchase management or accounting systems via system integration, ensuring comprehensive and accurate financial tracking.