Manufacturers put a lot of emphasis on keeping their equipment in good working order, and who could blame them? After all, this machinery not only forms the main apparatus through which they earn their money, but it also represents a serious capital investment. But even though manufacturers rightly spend a considerable amount of time and effort assessing and tending to the condition of their machines, they also cannot overlook the overall health of the buildings they call home.
Just like the machinery they house, buildings make up a huge portion of a manufacturer’s overhead. Keeping them in good shape is important first and foremost to protect the investment, but poorly maintained systems also can have a trickle-down effect that puts even the most well-oiled machinery at risk of breaking down and halting production. This is why it’s critical for manufacturing companies to conduct facility condition assessments (FCAs) on a regular basis. Doing so can save these companies a significant amount of money and stress, as long as they follow the right procedures.
What is a facility condition assessment (FCA)?
In the simplest terms, an FCA is a comprehensive look at the condition of a manufacturing facility. This means taking a close examination of all its various elements, including the structure itself as well as vital systems. Architectural features such as doors and windows also are included the assessment.
An FCA is crucial for facilities management and maintenance because it provides operators and owners with important information about their properties. It gives them an idea as to the overall health of the building as well as any areas that may be in need of attention, whether through maintenance, repairs or replacement.
Key components of a facility condition assessment
Each element of an FCA is essential for gaining the best understanding of a facility’s condition. Here’s what a typical facility condition assessment checklist will look like for most manufacturing operations:
- Visual inspections — During this phase, technicians take a close look at all components of the building. They check for any obvious signs of wear or neglect, such as crumbling walls, cracked windows, rusted metal, pest infestation and more.
- Systems evaluation — Once the physical condition of the building itself has been determined, it’s time to move on to assessing the plumbing, electrical, structural and HVAC systems.
- Performance testing — This means testing the functionality of essential systems including plumbing, electrical and HVAC. The purpose here is to ensure that not only they are working as effectively and efficiently as possible, but also that they are still meeting the needs of the manufacturer and doing everything they should to ensure the proper levels of productivity.
- Documentation review — Crews also need to take the time to review any relevant documents pertaining to the condition and upkeep of the building. These should include blueprints, maintenance records and previous facility condition assessment reports if they exist. This is important for context, as it can reveal any issues that may have existed in the past and whether they were adequately addressed.
- Rating and scoring — During this stage, technicians assign condition ratings and scores to all the various components they have assessed. This is important because it serves as the basis for any maintenance and improvement efforts that are to come, establishing the highest priorities and helping in the allocation of resources.
Steps to conduct a facility condition assessment
With the most important elements of an FCA in mind, it’s necessary to understand how they all fit together in a proper procedure. Here is a typical timeline for an FCA used in a manufacturing facility:
1. Preparation — At the onset, the focus should be on collecting all the most pertinent documents and tools that will be needed for the FCA. This also is the period during which manufacturers should establish the scope of the work as well as the facility condition assessment standards they intend to follow.
2. On site inspection — This is the main component of the FCA, as workers begin to perform the inspections and tests that will make up the bulk of the report.
3. Data collection — As technicians perform their inspections, they should be compiling meticulous records of their findings.
4. Analysis and reporting — Once the inspections are complete, the data is examined and a comprehensive report detailing the results is created.
5. Action plan — Based on the FCA report, manufacturers can develop an action plan for any maintenance or repair work that should be performed.
Benefits of facility condition assessments
Committing to an FCA can be a lot of work, but the benefits it provides are well worth the effort. Among the many advantages of conducting an FCA in a manufacturing facility are:
- Improved maintenance planning — Based on the results of the assessment, maintenance crews can have a better idea of which tasks should take the highest priority.
- Cost savings — Repairing or renovating entire portions of a building can be extremely expensive, but an FCA can detect potential issues so they can be corrected before they become worse.
- Enhanced safety — Addressing potentially hazardous conditions as soon as possible enhances worker safety and reduces the risk of injury in a manufacturing environment.
- Informed decision-making — An FCA provides an opportunity for data-driven insights that make budgeting and resource allocation a smoother and more effective process.
- Increased asset lifespan — With proactive maintenance empowered by an FCA, manufacturers can extend the life of their properties.
As manufacturers focus on keeping their assets in prime working order, they shouldn’t ignore their facilities. Beyond providing a fixed address, their properties also serve an important function in creating the right atmosphere for equipment to function at maximum efficacy. Performing an FCA on a regular basis is essential for manufacturers who want to get the most out of their facilities and maintain their competitive edge. With the information these assessments provide, they can stay on top of potential issues, resolving them before a more serious problem occurs.
