Discover how to align production with maintenance for efficient plant operations and minimize downtime with practical strategies in our latest article.

So for a maintenance tech, I first sought operators opinion or observations before delving in to correct issue. Once you understand actual problem, then you could start your process of troubleshooting. This builds relationships and solidifies "team" effort while helping you with a place at which to start your troubleshooting efforts. Its a win win situation that without a lot of effort can yield positive dividends.

Few key things, I have learnt and adapt which helped me bridge this gap 1) Communication : be transparent. the goal should be to help the business, not to put blame on anyone else. Soft skills play a crucial role. 2) Accept mistakes / shortcomings : if there is a miss, accept it. Do not try to brush is under the carpet or worse, look for a scapegoat. 3) Ask for support : dont hesistate in asking for support. Maintenance and Production, both should aim for a single purpose, betterment of the business. 4) Data driven : have a robust data management system, numbers speak louder than anything else. And the most important one ! the culture. the top leadership should foster a healthy culture between departments.

One idea that works is to have an everyday short stand-up meeting (morning huddle) where previous day, present day and the next day production is discussed.

Last updated on Jul 24, 2024

Struggling to bridge the gap between production and maintenance in Plant Operations?

In plant operations, the synergy between production and maintenance is crucial for efficiency and longevity. You might find it challenging to align these departments, often due to differing priorities: production focuses on output, while maintenance emphasizes equipment health. Yet, bridging this gap is essential. Effective communication and shared goals can transform these seemingly disparate functions into a cohesive unit, ensuring smooth operations and reduced downtime. Understanding each other's challenges and developing joint strategies can lead to a more harmonious and productive plant environment.

1 Align Goals

Harmonizing the objectives of your production and maintenance teams is the first step toward bridging the gap. Begin by establishing a common understanding that equipment reliability directly influences production targets. Encourage cross-departmental meetings to set mutual goals, such as maximizing uptime while minimizing breakdowns. By fostering a culture where both teams appreciate the impact of their work on the other, you lay the foundation for a collaborative approach to plant operations.

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Greg Leal

Leader Constellium Muscle Shoals
So for a maintenance tech, I first sought operators opinion or observations before delving in to correct issue. Once you understand actual problem, then you could start your process of troubleshooting. This builds relationships and solidifies "team" effort while helping you with a place at which to start your troubleshooting efforts. Its a win win situation that without a lot of effort can yield positive dividends.
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Bilal Bin Aftab, PMP®

Projects | Reliability | Maintenance | Engineering
Few key things, I have learnt and adapt which helped me bridge this gap 1) Communication : be transparent. the goal should be to help the business, not to put blame on anyone else. Soft skills play a crucial role. 2) Accept mistakes / shortcomings : if there is a miss, accept it. Do not try to brush is under the carpet or worse, look for a scapegoat. 3) Ask for support : dont hesistate in asking for support. Maintenance and Production, both should aim for a single purpose, betterment of the business. 4) Data driven : have a robust data management system, numbers speak louder than anything else. And the most important one ! the culture. the top leadership should foster a healthy culture between departments.
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Fawad Ahmed

Commercial Engineer at Kraft Food Industries / Nabisco Dammam 2004 --> 2017
The best way is participate in Daily plant meeting. Involve the operators and floor team. Have a close connect with operations team, open M&R request to all in the plant
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Arvind Charlewal
हमारे भारतीय समाज में एक परिवार निर्मित करने में पत्नि मुख्य भूमिका में होती है और पति एक अद्भुत सहयोगी की भूमिका में रहता है, पत्नि एक मकान को घर बनाती है और पति इसके लिए सभी जरूरी व्यवस्थाएं करता है ऐसा ही सम्बन्ध maintenance और operation teams के बीच होता है, यहा मुख्य भूमिका operation team की रहती है, तो सबसे बेहतर स्थिति तब बनती है जब maintenance team के सदस्यों को operation की Training देकर operation टीम का हिस्सा बनाए जाए, इन्हें मशीन के प्रत्येक कार्य की अच्छी जानकारी होती है, मशीन में ख़राबी आने की शुरुआत में ही समस्या को पहचाना जा सकता है, किसी भी बड़े ब्रेक डाउन से बचा जा सकता है नुकसान से बचा जा सकता है....

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rudi priyanto

Maintenance Manager di PT. Sunrise Steel
We go back to the basics of the maintenance philosophy, namely self maintenance or autonomos maintenance in the 8 pillars of TPM
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2 Enhance Communication

Effective communication is the lifeblood of any successful operation. To bridge the gap between production and maintenance, establish clear communication channels that allow for real-time updates and feedback. Implement regular briefings where both teams can discuss upcoming production schedules and potential maintenance issues. This proactive approach can help anticipate problems before they escalate, ensuring smoother operations and a more unified workforce.

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ADEWALE ADEKOYA, E.I.T.

Plant Operations Manager at Royal Foods Products
One idea that works is to have an everyday short stand-up meeting (morning huddle) where previous day, present day and the next day production is discussed.
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Abdus Salam

Project Engineer / Project Manager - Food / Dairy / Pharmaceutical / FMCG / Meat Industry
Ask Shift fitter/electrician to visit production hall at the end of shift and make sure all breakdowns listed on production downtime sheets are same as the ones recorded in maintenance downtime sheet.
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3 Cross-Training Staff

Cross-training your staff is a strategic move to reduce the divide between production and maintenance. When production workers understand basic maintenance procedures and vice versa, they develop a greater appreciation for each other's roles. This not only improves collaboration but also empowers employees to perform minor repairs or adjustments, reducing downtime and relieving pressure on maintenance personnel during peak production periods.

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Amanya Lawrence

Design Engineer | Maintenance Technician
Foster muldisciplined production staff to be equipped with basic maintenance skills to include cleaning, machine setup and optimization, repair of basic defective machine components, lubrication, adjustment and timing, participating in weekly scheduled maintenance and annual equipment Overhaul
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4 Shared KPIs

Key Performance Indicators (KPIs) can be powerful tools to align production and maintenance. Develop shared KPIs that reflect the interdependence of both functions, such as Overall Equipment Effectiveness (OEE). By tracking OEE, which combines availability, performance, and quality metrics, both teams can see the impact of their efforts on plant productivity. Shared KPIs encourage joint responsibility for outcomes and drive collective action towards improvement.

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5 Leverage Technology

Embracing technology can significantly ease the tension between production and maintenance. Invest in systems that provide real-time data on equipment performance and predictive maintenance alerts. This technology allows for preemptive action to prevent breakdowns, aligning maintenance schedules with production demands. By using such tools, both teams can work together more effectively, ensuring that maintenance activities support continuous production.

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6 Continuous Improvement

Lastly, adopting a philosophy of continuous improvement can help bridge the gap between production and maintenance. Encourage both teams to provide feedback on processes and collaborate on finding solutions to recurring issues. This iterative process not only enhances plant operations but also fosters a sense of ownership and partnership between the teams. As they work together to refine practices, the divide between them narrows, creating a more unified and efficient operation.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Struggling to bridge the gap between production and maintenance in Plant Operations?

1

2

3

4

5

6

7

1 Align Goals

2 Enhance Communication

3 Cross-Training Staff

4 Shared KPIs

5 Leverage Technology

6 Continuous Improvement

7 Here’s what else to consider

Plant Operations

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Struggling to bridge the gap between production and maintenance in Plant Operations?

1

2

3

4

5

6

7

1 Align Goals

2 Enhance Communication

3 Cross-Training Staff

4 Shared KPIs

5 Leverage Technology

6 Continuous Improvement

7 Here’s what else to consider

Plant Operations

Rate this article

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