What is MRO? A Guide to Effective Maintenance, Repair, and Operations

Successful manufacturing companies must implement a proper maintenance, repair, and operations (MRO) strategy to ensure their facilities are operating smoothly.

This article will discuss the importance of MRO, describe the main types of MRO maintenance, and outline best practices for an effective MRO strategy, which will help your organization reduce downtime, increase productivity, and lower costs.

What is Maintenance, Repair, and Operations (MRO)?

Maintenance, repair, and operations (MRO) includes all activities related to the maintenance, repair, replacement, and operation of any equipment, facilities, or assets a company relies on to achieve its goals. Inspecting a machine? That’s MRO. Replacing a window? That’s also MRO. Printing out a service manual? Changing a truck tire? You guessed it: MRO.

The purpose of MRO is to keep the machines, equipment, and facilities your organization depends on running smoothly, reducing the need for expensive, time-consuming repairs and delays. A proactive MRO strategy will help your organization prevent unplanned downtime, improve efficiency and productivity, and minimize costs.

MRO also plays an important role in ensuring worker safety. Faulty equipment or facilities can pose a serious risk to workers. And regular maintenance and repair of both equipment and facilities can help you preemptively identify and prevent potential hazards.

In other words, MRO is vital to ensuring your organization stays up and running.

The 3 Types of MRO Maintenance in the Manufacturing Industry

MRO in the manufacturing industry encompasses a wide variety of activities, ranging from the repair of infrastructure to the storage of consumables and tools to the maintenance and repair of production equipment.

But any successful MRO strategy depends heavily on implementing an effective maintenance program. MRO-related maintenance can be broken down into three main categories: corrective, preventive, and predictive maintenance. (Though, increasingly, many MRO teams are looking to condition-based maintenance strategies as well.)

1. Corrective Maintenance

Corrective maintenance involves repairing equipment or facilities that have already failed or malfunctioned. This type of maintenance is typically reactive (unplanned), so it can result in significant downtime and increased costs. Corrective maintenance is often necessary for unexpected failures, but it should not be the primary focus of your MRO strategy.

2. Preventive Maintenance

Preventive maintenance involves scheduled maintenance and inspections of equipment and infrastructure aimed at preventing breakdowns and extending asset lifespans. This type of maintenance is proactive and can help reduce downtime and lower costs by identifying and addressing potential issues before they become significant problems. A successful preventive maintenance program also ensures your organization’s storerooms and technicians always have the right materials in the right place at the right time.

3. Predictive Maintenance

Predictive maintenance involves using data and analytics to predict when maintenance will be required in the future. Any MRO strategy can be greatly improved by deploying advanced tools and sensors (such as vibration sensors from Fluke Reliability) to continuously and effortlessly monitor the health of mission-critical assets. Such data-collection tools can also be paired with a computerized maintenance management system (CMMS) software like eMaint. This gives maintenance teams access to both real-time and historical data and trends, which enables the identification of potential issues before they become problems, ultimately increasing productivity.

Best Practices for an Effective MRO Strategy

Implementing an effective MRO strategy requires a comprehensive approach that involves several key best practices.

1. Develop a Comprehensive MRO plan

Any effective MRO strategy involves having a comprehensive plan that outlines the maintenance, repair, and replacement activities required to maintain equipment, facilities, and operations. That plan should include a schedule of preventive maintenance activities, as well as a process for handling unexpected failures.

2. Use Data and Analytics

Data and analytics can provide valuable insights into equipment and facility performance, allowing manufacturers to identify potential issues before they become problems. By electronically capturing equipment and facility data, organizations can implement a predictive MRO strategy that gives maintenance teams and leadership the information they need to make data-driven decisions about repairs and replacements.

3. Invest in Training and Development

Properly maintaining and repairing equipment and facilities requires specialized knowledge and skills. Investing in training and development for maintenance staff can help ensure they have the skills they need to effectively perform necessary maintenance and repair activities.

4. Use Technology to Streamline MRO Activities

Technology can play a significant role in improving any MRO strategy. Manufacturers can use technology to automate maintenance tasks, monitor equipment and facility performance, and streamline the repair and replacement process. All MRO-related activities should also be documented, which can help reveal trends and potential issues early. Keeping consistent, accurate documentation is made much easier by deploying CMMS software such as eMaint.

By committing to an MRO strategy that focuses on preventive and predictive maintenance, employee training, and technology-driven data collection and documentation, your organization will ensure all equipment, tools, and facilities are as well-maintained and productive as possible.