AndonCloud

Maintenance processes can be streamlined using digital tools, which are more cost-effective than traditional methods. More and more companies, both large manufacturing plants and smaller enterprises, are using systems that allow for better planning of inspections, faster response to breakdowns, and extended machine life. One such solution is CMMS (Computerized Maintenance Management System) – a system that enables comprehensive management and documentation of maintenance activities. Research shows that well-implemented CMMS systems can help reduce operating costs and improve production stability.

CMMS systems are no longer a niche solution. According to Market Research Future forecasts, the global CMMS market will grow from approximately $2.32 billion in 2025 to $5.10 billion in 2034, with a compound annual growth rate (CAGR) of 9.12%.
More and more companies are recognizing the benefits of digitizing maintenance processes. Research shows that about 72% of companies use CMMS systems, and nearly half of them use predictive maintenance features that allow them to anticipate failures before they occur. 74% of companies report that implementing CMMS has contributed to increased productivity.
These data show that CMMS is no longer just an additional support for the technical department, but is becoming a key element of the maintenance and digitization strategy of companies.

CMMS enables centralised management of all maintenance tasks, including inspection planning, machine performance monitoring and failure cause analysis. The system facilitates effective response to problems, optimises maintenance schedules and increases machine availability.

Thanks to CMMS, operators can report faults directly from mobile devices, attaching descriptions, photos, or videos. This reduces response times and improves the efficiency of technical teams. The system also allows tasks to be assigned to the right people, priorities to be set depending on the situation on the shop floor, and work progress to be monitored in real time. This mechanism enables quick detection of problems and optimization of activities in a dynamic production environment.

The implementation of a planned approach to maintenance, including autonomous maintenance (AM), can significantly reduce the number of unplanned breakdowns. Autonomous maintenance, which is part of the Total Productive Maintenance (TPM) concept, allows operators to identify problems early and perform basic maintenance tasks such as cleaning and lubrication. Research by the Japan Institute of Plant Maintenance indicates that involving operators in such activities can reduce minor faults by 10-15% per year. In addition, implementing a proactive maintenance strategy can reduce unplanned downtime by as much as 30-50% and increase overall equipment effectiveness (OEE).

For directors and maintenance managers, CMMS is a strategic tool that supports budget planning, performance evaluation, and performance indicator monitoring. The system provides access to a complete history of failures, repairs, and costs, allows you to control the implementation of preventive plans, and quickly analyze MTBF, MTTR, and downtime costs. It also allows you to assess team workload and plan resources effectively. In addition, CMMS supports certification and audit compliance. Reports indicate that 28% of CMMS users consider the reduction in unplanned downtime to be the greatest value of the system.
In practice, this means that the maintenance director no longer has to act solely reactively—they can predict costs, plan resources, and compare the effectiveness of activities over time. This shifts the role of the maintenance department from "firefighting" to actively supporting the development and competitiveness of the entire plant.

Market data shows that companies that have implemented CMMS and moved from a reactive to a preventive maintenance model see a 25-35% reduction in maintenance costs in the first year of use. Machine reliability improves by 40-50%, which translates into greater equipment availability and fewer breakdowns.

These benefits extend beyond the maintenance department itself—they affect the efficiency of the entire plant. Companies report less downtime, better utilization of human resources, reduced operating and storage costs through inventory optimization, and improved work safety and regulatory compliance. What's more, the system supports process digitization by enabling integration with IoT and real-time data analysis.

The AndonCloud platform integrates CMMS functions with the MES (Manufacturing Execution System), creating a coherent application for managing both production and maintenance. The system enables quick fault reporting, planning and monitoring of inspections, use of checklists and schedules, as well as analysis of MTBF and MTTR indicators. By using historical data and signals from machines, it is possible to implement predictive maintenance, and operators can actively participate in the daily monitoring of machine condition. Integration with MES gives management a complete picture of the production and technical situation, enabling them to make decisions based on real data.

CMMS is a tool that streamlines maintenance management, organizes information, and supports both technicians and management. More and more companies are implementing CMMS systems, and investments in predictive maintenance and process digitization are becoming standard in the industry. AndonCloud goes a step further by combining CMMS and MES functions, providing full visibility into the production floor and maintenance department, realistically increasing plant efficiency, and supporting development towards Industry 4.0 and 5.0.