Why is it not enough to solve problems only when they arise?

In industrial plants, the reliability of production equipment is crucial. Unexpected failures not only increase repair costs, but also lead to delivery delays, production disruptions and reduced efficiency.

But how can problems be solved before they occur?

From reactive to predictive maintenance

Many companies still operate on the principle of reactive maintenance, that is, they repair equipment only when it breaks down. However, this approach increases the cost of unplanned downtime and shortens the life of the machines. Modern EAM systems, such as HEXAGON EAM, enable the transition to predictive maintenance, where failures are identified and resolved before they occur.

The system uses condition monitoring, historical data analysis and artificial intelligence to detect wear patterns. This means it can predict when maintenance will be needed, minimizing the number of emergency repairs and reducing downtime.

Key benefits of the EAM system in practice

Implementing EAM solutions brings several benefits to manufacturing companies:

  • Reducing production downtime – Predictive analytics helps plan maintenance so that it does not affect business operations.
  • Lower maintenance costs – Better planning means fewer emergency repairs and more efficient use of spare parts.
  • Longer machine life – Properly timed maintenance extends the life of equipment.
  • Increased safety – Identifying risks before they occur minimizes danger to workers.
  • Better cost control – The business gains a detailed overview of maintenance costs and can plan the budget more effectively.

If you are interested in how HEXAGON EAM helps in real conditions, check out these case studies: How EAM system improved asset management in the gas industry and Implementing EAM in the field of heat and hot water production. Thanks to our solution, you will reduce maintenance costs by up to 50%, your machine downtime will decrease by 20% and your work productivity will increase by 20%.

How to implement an effective maintenance system?

For the successful implementation of an EAM system, it is necessary to proceed in several steps:

  1. Current status analysis – Identification of major problems in maintenance and production processes.
  2. Data collection and digitization – Creating a database about machines, their performance and failure history.
  3. System implementation – Integration with existing manufacturing and ERP systems.
  4. Setting up predictive algorithms – Using data analytics and IoT sensors to monitor the health of devices.
  5. Continuous optimization – Continuous improvement of processes based on acquired data.

Our modern EAM systems allow you not only to monitor the condition of your assets, but also to automatically generate work orders, manage spare parts, and optimize your maintenance budget.

The Future of Maintenance: AI and Automation

With the development of artificial intelligence and IoT, maintenance is constantly evolving. Sensors embedded in machines can send real-time data about their condition and predict component wear. Combined with AI, the systems become an invaluable tool for production managers who want to prevent problems before they occur.

Investing in an effective asset management system is not just about short-term savings, but about long-term competitiveness and production reliability. If you are still operating on a “fix it when it breaks” basis, it is high time to move to modern solutions that allow you to anticipate and prevent problems.

Want to learn more about how HEXAGON EAM can help your production? Contact us and we will be happy to present you a solution that will improve your maintenance efficiency!

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