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Unlocking Peak Manufacturing Maintenance Performance: How Maintenance Practices Echo Along the Supply Chain

maintenance supply chain post Unlocking Peak Manufacturing Maintenance Performance: How Maintenance Practices Echo Along the Supply Chain

Return on Assets (ROA) stands as a critical barometer of operational efficiency and financial health in the intensely competitive manufacturing arena. It’s more than a number; it’s a reflection of how effectively a company uses its assets to generate profits. However, lurking in the background, often underappreciated, is the role of maintenance in shaping this vital metric. Poor or non-existent maintenance practices can significantly dent ROA. In the fifth article of our series, “Unlocking Peak Manufacturing Maintenance Performance,” we examine the top 10 ways maintenance standards and practices directly influence ROA in manufacturing.

Understanding ROA: Maintenance as a Financial Catalyst

ROA, calculated by dividing a company’s net income by its total assets, offers a clear window into how well its resources are being utilized to produce profits. In manufacturing, where assets predominantly include machinery and equipment, maintenance emerges as a pivotal player in preserving and maximizing these assets’ value. 

Exploring the Top 10 Maintenance Factors Impacting ROA:

1 Escalated Downtime Costs:

Subpar maintenance can increase unplanned downtime by 15-30%, translating to significant production hours losses. Each hour of downtime is an hour where assets are not generating revenue, directly lowering ROA.

2 Soaring Repair and Replacement Expenditures:

Neglected maintenance often leads to a 50% rise in repair costs and a 30-50% increase in the frequency of equipment replacements. This inflates expenses and means diverting capital to replace assets rather than investing in growth opportunities.

3 Diminished Equipment Efficiency:

When equipment isn’t maintained, its efficiency can drop by up to 20%. This decrease means assets are not being used to their full potential, negatively impacting production output and profitability.

4 Quality Control Compromises:

A 10-20% increase in defect rates due to poor maintenance results in additional rework and quality control costs. These added expenses reduce the profit generated per asset, negatively affecting ROA.

5 Safety-Related Financial Burdens:

A 10-20% rise in safety incidents due to poor maintenance can lead to expensive legal liabilities, compensation, and fines, all of which decrease net income and, thus, ROA.

6 Elevated Energy Bills:

Inefficiently running machinery can consume up to 30% more energy, leading to higher operational costs. These increased costs reduce the profitability per asset.

7 Inventory Management Disruptions:

Inaccuracies in inventory, heightened by 5-10% due to maintenance issues, can cause delays and additional costs, impacting the efficiency of asset utilization.

8 Labor Cost Inflation:

A lack of proper maintenance can necessitate up to 30% more overtime labor, leading to increased wage expenses that reduce net income and ROA.

9 Extended Production Cycle Times:

Poorly maintained equipment can prolong cycle times by 5-15%, leading to reduced throughput and less efficient use of assets.

10 Regulatory Compliance Expenditures:

Maintenance lapses can increase non-compliance risk by 5-20%, potentially resulting in fines and operational stoppages that adversely affect profitability and asset utilization.

The POWERS Strategy:
Elevating ROA through Maintenance Excellence

At POWERS, we recognize that maintenance is not just about keeping equipment running; it’s about strategic asset optimization. Our Advanced Maintenance Performance (AMP) program is tailored to enhance your maintenance protocols, thereby improving ROA by ensuring that your assets are utilized efficiently and effectively.

Our comprehensive approach involves meticulously analyzing your current maintenance strategies and their impact on ROA.

We provide specialized training and strategic planning, focusing on enhancing your equipment’s efficiency, reliability, and lifespan. By optimizing these aspects, we aim to boost your net income and ROA, turning your maintenance operations into a key driver of financial success.

To discover how optimized maintenance can transform your company’s ROA, download our FREE Maintenance Assessment Guide. Embark on a journey towards maximizing asset value and bolstering your bottom line.

Contact the POWERS team at +1 678-971-4711 or email info@thepowerscompany.com for a comprehensive consultation to reshape how you view maintenance and asset management.

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