How often do your contractors or rental customers call out engineers for unexpected equipment faults or failures, be they mechanical, electrical or user-created? It is a perennial problem. However, technology and aligned processes can remove the productivity obstacle by eliminating the need for service engineers to return to machines multiple times.
Right-first-time (RFT) maintenance is a proactive approach aimed at performing maintenance tasks accurately on the first attempt, thereby minimizing defects, rework, and downtime. Originating in manufacturing and now expanding across construction, RFT has become integral to modern total quality management (TQM) practices, leveraging connectivity and diagnostics to resolve issues accurately at the first attempt.
While that might sound like any maintenance process, it differs in that traditional maintenance tends to be reactive, some times quick-fix in nature, and often prone to rework. Traditional maintenance typically relies on fixed schedules, often without real-time machine data. This can lead to misdiagnosis, unnecessary part replacements, or incomplete fixes, resulting in repeat visits.
But, according to McKinsey, predictive and data-informed approaches like RFT can reduce maintenance costs by 18 to 25% and improve asset availability by 5 to 15%. By focusing on precision and quality in maintenance, RFT can deliver significant cost savings and operational improvements, especially for industries that rely heavily on equipment uptime, such as construction.
Implementing RFT maintenance principles can lead to measurable savings and enhancements in operational efficiency:
Reduced downtime: Addressing equipment issues promptly and accurately can significantly reduce downtime, which is crucial in industries like construction, where equipment breakdowns can delay projects and increase costs. Most research in this area is drawn from facilities management operators where the research shows that companies practising preventative and RFT maintenance experience substantial reduction in downtime. A study by Aberdeen Research & Study found that companies with unplanned downtime experience 20% decrease in worker productivity.
“RFT can deliver significant cost savings and operational improvements, especially for industries that rely heavily on equipment uptime, such as construction.”
Lower maintenance costs: RFT minimizes the need for repeated repairs and the consumption of spare parts, thus reducing maintenance costs. By getting repairs right the first time, organizations can cut overall maintenance costs by 12-18%, with maintenance labour costs reduced by as much as 15-25% since fewer hours are needed to revisit unresolved issues.
Enhanced equipment reliability: When maintenance tasks are executed accurately on the first attempt, equipment is more likely to operate consistently without unexpected failures. This not only extends the lifespan of machinery but also improves safety by lowering the risk of equipment-related accidents.
RFT maintenance contributes to cost savings in multiple ways. Maintenance tasks performed correctly on the first attempt reduce the need for additional labour, freeing up personnel to focus on preventive or strategic tasks.
Effective maintenance practices help reduce inventory levels and associated carrying costs by decreasing the need for spare parts used in rework. With fewer parts consumed, inventory turnover rates improve, leading to a more streamlined supply chain.
Correcting faults early and avoiding inefficient equipment operation can result in energy savings. In industries with heavy equipment, RFT practices can yield up to 20% reductions in energy consumption due to decreased strain and more efficient engine operation resulting in reduced operating times associated with the work.
The nature of construction machinery maintenance involves unique challenges that make RFT approaches even more critical. Construction machinery often consists of numerous specialised components, making it difficult to diagnose issues accurately.
This complexity requires a comprehensive approach to maintenance, which includes well-trained technicians and advanced diagnostic tools. Construction sites expose equipment to extreme conditions like mud, dust, and vibrations, which accelerate wear and tear.
Machine owners need an approach that ensures maintenance practices are robust enough to address these challenges from the outset, preventing unnecessary and avoidable parts deterioration.
Managing a mixed fleet with various makes and models adds complexity to maintenance scheduling and parts sourcing. RFT maintenance mitigates this issue by standardizing processes to achieve higher accuracy in diagnostics and repairs across different equipment types.
Technological advancements have significantly enhanced the feasibility and effectiveness of effective maintenance. Tools including IoT sensors and predictive analytics enable real-time monitoring of equipment, which facilitates early detection of potential problems.
The benefits of incorporating technology to assist in reducing costs and eliminating non-productive equipment on-site include using data analytics and machine learning to anticipate equipment failures before they occur.
McKinsey & Company found that predictive approaches utilising digital maintenance and reliability processes can reduce maintenance costs by 18-25%, as repairs can be scheduled based on the actual condition of the equipment rather than fixed intervals.
Ensuring the fleet is fitted with connected technology, technicians can remotely assess equipment conditions and prepare for repairs in advance. This reduces the time spent on manual inspections and increases the accuracy of repair work.
IoT devices continuously gather data on equipment health, providing insights that help maintenance teams make data-driven decisions. Automated alerts can trigger maintenance activities when abnormal conditions are detected, ensuring timely interventions and minimising disruptions.
A fit-for-purpose platform and tools allow customers to quickly benefit through integrating technology with their maintenance strategies. The platform helps deliver:
Data monitoring: The connected hardware collects detailed machine health metrics, such as engine temperature and fluid levels, allowing maintenance teams to detect irregularities early.
Predictive analytics: Machine learning algorithms predict when components are likely to fail based on historical data, enabling pre-emptive repairs that prevent equipment breakdowns.
Remote diagnostics: The platform allows technicians to perform diagnostics remotely, reducing the need for onsite inspections and ensuring repairs are conducted efficiently.
Transitioning to RFT and preventative maintenance practices with the support of a suitably robust technology platform and tools offers substantial financial benefits:
Extended equipment lifespan: Addressing maintenance issues accurately on the first attempt reduces wear and tear on machinery, extending its useful life. This reduction in the need for more frequent replacements can lower capital expenditures by up to 15% over the long term.
Higher return on investment: Reducing maintenance costs and enhancing equipment uptime should result in a better ROI. Preventative maintenance will ensure equipment functionality, extend useful machine life and reduce Total Cost of Ownership (TCO) with construction firms practising RFT anecdotally reporting ROI improvements of up to 25% due to increased operational efficiency and lower repair costs.
People at the center: High quality employees are a key asset to any business. Maintenance is no exception, and organizations need to implement programs that capture skills and allow for upskilling of all maintenance staff. Encouraging experienced technicians to record, codify and share their knowledge helps other team members to become more productive and retains specific skills within the workforce.
Optimized project scheduling: Fewer equipment failures mean projects experience less downtime, which helps keep schedules on track and avoids penalties for late completion. Project timelines can improve by up to 20% with a proactive maintenance approach, especially when combined with predictive maintenance technologies. A major UK construction business has adopted a proactive maintenance strategy, utilizing predictive analytics to anticipate equipment failure, which has reportedly decreased equipment-related downtime across its infrastructure projects.
OEMs can support enhanced maintenance by leveraging data collected through connected systems to optimize maintenance protocols. By analyzing data trends, OEMs can adjust recommended maintenance intervals based on real-world equipment usage rather than fixed schedules.
“RFT maintenance not only saves money but also extends equipment life and boosts project outcomes.”
This approach improves equipment reliability and minimizes unnecessary maintenance costs. OEMs can use failure data to identify design flaws and improve the durability of specific components, further enhancing RFT outcomes.
Manufacturers are increasingly involved with construction companies to refine maintenance strategies and provide targeted training to improve first-time repair accuracy.
Dealers too can remotely diagnose issues through telematics to ensure mechanics with the correct skillset are dispatched to the machine and that the correct parts also go to the machine.
RFT maintenance represents a shift from traditional reactive maintenance to a more proactive, precision-based strategy.
As industries increasingly adopt more effective maintenance practices, supported by technological advancements in telematics and predictive analytics, companies are poised to reap the benefits of reduced costs, enhanced safety, and improved productivity.
The evidence indicates that RFT maintenance not only saves money but also extends equipment life and boosts project outcomes.
For companies aiming to stay competitive, integrating these principles into their maintenance programs is not just a cost-saving measure but a strategic investment in operational excellence.
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