5 ways AI can improve your Maintenance Management Strategy

Jun 10, 2024

McKinsey estimates that by 2030, artificial intelligence (AI) could generate an extra $13 trillion in global economic activity or a 16% increase in total GDP above current levels (McKinsey, 2018). In today’s fast-paced industrial environment, equipment maintenance and efficient facilities are more important than ever. Traditional maintenance management strategies, while effective to a certain extent, often fall short when it comes to predicting issues and optimizing resources. 

This is where Artificial Intelligence (AI) steps in, offering innovative solutions that can improve your maintenance strategy optimization plan significantly. With its ability to analyze vast amounts of data and generate actionable insights, AI can help you move from a reactive to a proactive maintenance approach.

Artificial Intelligence (AI) is improving maintenance management by introducing advanced capabilities beyond traditional methods. AI involves using algorithms and machine learning techniques to analyze vast amounts of data, identify patterns, and make intelligent decisions. In maintenance management, AI can predict equipment failures, automate routine tasks, and generate insights for equipment maintenance that improve operational efficiency. 

McKinsey predicts that by 2030, automation may replace jobs accounting for 21.5% of total hours worked in the US economy. With generative AI, this figure rises to 29.5% (McKinsey, 2023). Generative artificial intelligence for industry, a subset of AI, specifically focuses on creating new content and solutions based on existing data. For maintenance management, generative AI can automate the creation of standard operating procedures (SOPs), generate detailed maintenance documentation, and provide real-time insights and recommendations. 

1. AI-Generated Standard Operating Procedures

AI-generated SOPs ensure that your procedures are comprehensive and up-to-date with the latest industry standards and best practices. This advanced technology can analyze vast amounts of data to produce precise and consistent SOPs tailored to your specific needs. 

A. Consistency and accuracy

AI-generated standard operating procedures (SOPs) ensure that all your maintenance strategy optimization processes are consistent and accurate. With AI, you can automate the creation of SOPs, eliminating human error and ensuring that every procedure is detailed and precise. This consistency means that all team members follow the same guidelines, reducing confusion and ensuring that tasks are completed correctly every time. 

B. Time savings

48% of facilities permit linked devices to be used for information technology and machine data collecting while monitoring industrial equipment maintenance (Plant Engineering, 2021). Creating and updating SOPs manually can be a time-consuming process, often requiring input from multiple team members. With AI, you can automate this process, allowing the system to quickly generate or revise SOPs based on the latest data and best practices. 

C. Improved compliance

68% of manufacturers said their safety program was “good, but needs improvement” (Advanced Technology, 2020). By using artificial intelligence for industry to create and update your SOPs, you can ensure that all procedures adhere to the latest legal and safety requirements. 

This reduces the risk of non-compliance and potential fines, while also enhancing the safety and quality of your operations. With AI, you can have peace of mind knowing that your maintenance strategy optimization procedures are always up-to-date and compliant with all necessary regulations.

2. Automated Inventory Management

Automated inventory management using AI transforms the way you handle your maintenance supplies. By leveraging generative AI, you can streamline inventory processes, ensuring that stock levels are always optimized and that critical items are readily available when needed. 

A. Optimized stock levels

Automated inventory management with AI helps you maintain optimized stock levels by accurately predicting your inventory needs. Generative AI analyzes historical data, current usage patterns, and market trends to forecast future demand. This ensures that you always have the right amount of stock on hand, avoiding the pitfalls of overstocking or running out of essential items. 

B. Improved efficiency

BCG clients have discovered that by making better decisions about productivity drivers such as machine setups, the EBITDA effect can reach +8% (Boston Consulting Group, 2023). AI-powered inventory management significantly improves efficiency by automating routine tasks such as stock tracking, reordering, and reporting.

Instead of manually checking inventory levels and placing orders, AI systems can monitor stock in real time and automatically reorder supplies when they reach predefined thresholds. This reduces the burden on your team, freeing them up to focus on more critical maintenance strategy optimization activities. 

C. Cost savings

A vast array of technologies that improve maintenance work and result in 15–30% cost savings are included in digital work management (McKinsey, 2021). Implementing automated inventory management with AI can lead to substantial cost savings for your organization. By optimizing stock levels, you reduce the capital tied up in excess inventory and minimize storage costs. 

The improved efficiency from automating inventory tasks also lowers operational costs by reducing the need for manual labor and minimizing errors that could lead to costly mistakes. Furthermore, AI-driven insights can help you negotiate better deals with suppliers based on accurate demand forecasts, further driving down costs. 

Maintenance Management

Summary of maintenance tasks supercharged by AI

3. Advanced Voice Transcriptions

Advanced voice transcriptions powered by generative artificial intelligence for the industry can change the way you manage maintenance records and communication. AI accurately transcribes spoken words into text, ensuring that every detail of maintenance strategy optimization activities is captured precisely. 

A. Improved documentation

With advanced voice transcriptions, you can significantly improve the quality and accuracy of your documentation. Generative AI can transcribe spoken words into detailed, precise text, capturing every nuance of maintenance activities. This means you no longer have to rely on handwritten notes or memory to document tasks and procedures. Instead, you can have comprehensive and accurate records that are easy to reference and store. 

B. Enhanced communication

The likelihood of transformation success rises from 30% to nearly 79% with commitment and action in all pertinent change domains, particularly communication (McKinsey, 2020). AI-driven voice transcriptions also enhance communication among your maintenance team. 

By transcribing meetings, discussions, and instructions, everyone has access to the same information, reducing the risk of misunderstandings and ensuring that all team members are on the same page. This is particularly useful for complex maintenance strategy optimization tasks that require clear and precise instructions.

C. Increased productivity

Operators that have used AI in industrial processing plants have reportedly seen increases in production of 10 to 15 percent and EBITA of 4 to 5 percent, according to McKinsey (McKinsey, 2023). Advanced voice transcriptions can significantly boost productivity by automating the documentation process. Instead of spending time writing down notes or typing up reports, your team can focus on more critical tasks. 

The AI system handles the transcription quickly and accurately, freeing up valuable time and resources. This increased productivity means that your maintenance team can accomplish more in less time, improving overall efficiency and allowing you to allocate resources to areas that need them the most. 

4. AI-Driven Maintenance Documentation

AI-driven maintenance documentation is transforming how you manage and record maintenance activities. By utilizing generative AI, you can automate the creation of detailed and accurate maintenance records, reducing the burden of manual documentation. 

A. Accuracy and detail

84 percent of corporate executives, according to Accenture, think that using AI is necessary to meet their growth goals (Accenture, 2019). Generative AI ensures that your maintenance documentation is both accurate and detailed. Instead of relying on manual entries, which can be prone to errors and omissions, AI can capture and document every aspect of a maintenance task with precision. 

This includes detailed descriptions, timestamps, and any relevant data from sensors or logs. By ensuring that your documentation is thorough and exact, you can better track maintenance activities, identify patterns or recurring issues, and make informed decisions based on reliable data. 

B. Time efficiency

According to a PwC survey, key findings in Northwest Europe showed that although there is an increasing interest in digital solutions, implementation levels are still comparatively low (PwC, 2024). AI-driven maintenance documentation significantly enhances time efficiency by automating the documentation process. Manually recording maintenance activities can be time-consuming and tedious, taking valuable time away from more critical tasks. 

With artificial intelligence for industry, the documentation is created in real-time as the maintenance work is performed, ensuring that records are up-to-date without the need for manual input. This automation allows your team to focus on their primary responsibilities, reducing administrative overhead and increasing overall productivity. 

Makula can help you streamline your business processes with digital maintenance forms, ensuring accuracy, efficiency, and compliance. Improve your maintenance strategy today!

5. AI-Driven Workflow Automation

AI-driven workflow automation revolutionizes the way you manage maintenance tasks by streamlining processes and reducing manual intervention. By using generative AI, you can automate routine workflows, ensuring that tasks are completed efficiently and consistently. 

A. Increased efficiency

An estimated $50 billion is lost by industrial firms each year due to unplanned downtime, with 42% of this unscheduled downtime being the result of equipment malfunction (Industry Week). AI-driven workflow automation significantly boosts efficiency by automating repetitive and time-consuming tasks. Instead of manually scheduling maintenance, tracking progress, or generating reports, AI systems can handle these activities seamlessly. 

This means you can streamline your workflows, ensuring that tasks are completed faster and with fewer errors. By reducing the administrative burden on your team, they can dedicate more time to critical maintenance activities that require human expertise. 

B. Consistency and accuracy

Automated workflows ensure that tasks are performed the same way every time, adhering to predefined standards and protocols. This reduces the variability that can occur with manual processes and ensures that maintenance activities are completed correctly and on schedule. AI can also accurately track and log every step of the workflow, providing detailed and precise records that can be used for auditing and analysis. 

Streamline your maintenance tasks with Makula’s Work Order Management. Our platform automates work orders, assigns tasks efficiently, and tracks progress in real time, ensuring your maintenance operations run smoothly and effectively.

C. Scalability

AI-driven workflow automation provides the scalability needed to grow and adapt your maintenance operations as your organization expands. With automated systems in place, you can easily scale up your maintenance activities without a corresponding increase in manual effort or administrative overhead. AI can handle larger volumes of data and more complex workflows, allowing you to manage additional assets and maintenance tasks efficiently. 

AI can greatly improve your maintenance management by predicting issues, automating tasks, and providing detailed insights. These advancements lead to increased efficiency, cost savings, and consistent, accurate operations. Staying ahead with AI-driven solutions is essential for maintaining high standards and staying competitive. 

Looking to get ahead by leveraging top maintenance management strategies? Check out Makula, and book a demo today.


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