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“UpKeep revealed we had an overage in inventory and lets us make more cost-effective decisions. It was literally the difference between $1.4 million in parts versus $500,000.”
National Reliability Manager at Rehrig
Prioritize work orders, reduce equipment downtime, and increase asset lifespan with the power of UpKeep.
This article discusses the asset life cycle and the impact of design, procurement, installation, commissioning, and O&M phases on total life cycle costs.
Overall, the main mistakes I’ve seen with lubricating bearings have to do with either too much lubrication or too little.
Straight Line Depreciation is an accounting method, and accounting is not the first thing you might associate with maintenance.
Our goal is to dig deeper and understand why good people make bad decisions. Moreover, we have to regard RCA as a system and not just a task.
World-class manufacturing facilities successfully stay ahead of breakdowns, achieve higher asset utilization, reduce maintenance costs, and increase safety.
Asset management is generally defined as a system of activities that an organization performs to gain value from assets, including design and maintenance.
To answer that, we should first understand exactly what causes rotating equipment to fail. The majority of failures come down to unbalance and misalignment.
Reliability engineering is a complex process with lots of room for potential errors, lost time, and wasted money. Stay forward thinking and proactive.
Finding causes of problems can be tricky, and convincing maintenance technicians to accept new practices can be even trickier. Here are some ideas to help:
The most common ISO standards to follow for manufacturing facilities are ISO 55000, 55001, and 55002. All require an asset management system.
A bathtub curve is a visual of a product's failure rate over time that maps out three periods that an asset experiences within its lifetime.
When it comes to equipment failure, there are a few interesting trends that we see. We can see some of the challenges effective reliability planning.
In maintenance, a turnaround is an event where one or more assets are temporarily removed from service so that maintenance tasks can be performed.
Maintenance management is the process of maintaining a company’s resources. It ensures efficient production and effective use of resources.
You should budget approximately 2% to 5% of your total RAV. This metric, known as %RAV, is calculated as a proportion of your facility's value and spending.
A fixed asset is one of two major categories of physical property for a company and includes those items that remain in one location during business operation.
Purchase orders (POs) are created to start a purchasing relationship with an outside vendor. POs include quantity, delivery schedule, and payment terms.
Some of the most common root cause analysis mistakes involve poor definitions, focusing on the wrong thing, or ignoring root causes entirely.
For root cause analysis to be effective, you need to dig deep, have the right resources, and ask “Why?” until you get to a root cause.
To measure performance in inventory management, one of the most common metrics to use is “number of inventory turns" and target a value greater than 1.0.
The collection of equipment failure data over time determines the reliability of your facility and enables proper asset management and life-cycle analysis.
A function describes the intention of a piece of equipment, while functional failures detail conditions that would prevent equipment from peak operation.
In order to decide if it is time to repair or replace an asset, you must compare the current value of the asset with the cost of repair.
Equipment depreciation is a measure of how much a piece of equipment drops in value each year. Using depreciation, you can make wiser maintenance decisions.
An asset life cycle refers to the stages involved in the management of an asset. The life cycle of an asset starts with the planning stages.
Availability measures equipment's ability to operate, while reliability measures the ability of equipment to perform without failure.
Idle time is the time in which an asset is either waiting to run or isn’t scheduled to run and downtime is when the asset is incapable of running.
Criticality is a measure of how important an asset is to your process. The more critical the asset, the more of an impact it will have if fails.
Assistive devices help individuals with disabilities live a more independent life by using technology and increasing everyday accessibility.
Overall equipment effectiveness (OEE), the most common metricperformance of a plant, is expressed as a percentage of the total production time.
Indicators are classified according to whether they predict future performance or describe past performance –- referred to as leading or lagging indicators.
There are numerous ways to improve your equipment uptime, each of which has to do with streamlining your maintenance processes.
Downtime and uptime are the heartbeats of a manufacturer - when the facility has too much downtime, the health of the organization suffers.
Maintenance tasks for indoor cycling bikes include daily, weekly and monthly cleaning, inspection, and adjustments to ensure strong durability.
Breakdown time is downtime that results from the equipment breaking down. Equipment downtime is any time a piece of equipment is offline.
The maintenance unit cost is a snapshot of the total maintenance cost required to manufacture a standard unit of production during a set period of time.
When implementing total productive maintenance (TPM), I think it’s best to gradually phase it in. It will enable an organization-wide adjustment over time.
Use failure codes systematically: start with analyzing the reasons for failures, code this information in a consistent way, and make it accessible.
The SMRP identified five pillars of maintenance and reliability to help facility managers create a framework for their businesses.
One such goal is to strive for spending 3 percent or less of your replacement asset value (RAV) annually on maintenance costs. Here are the details.
Both bar codes and RFID tags can help you track your assets and equipment; and each has its own unique advantages and disadvantages.
IRS Publication 946, Appendix B, lists useful life estimates by industry and application. These estimates can be used as a baseline.
Either you replace old equipment, or you keep it around. The route you choose depends on your facility’s current demands.
The primary difference between a PLC (or Programmable Logic Controller) and SCADA is the fact that a PLC is hardware and SCADA is generally software
When MTBF is presented you cannot instantly ascertain whether the metric is being influenced more by the uptime duration or by the number of breakdowns.
The short answer to the question is generally “no”. However, asking the question sets into motion the bigger issue of how to evaluate any metric in facilities management.
Implementing a good electric motor testing (EMT) program can be a massive positive investment in the reliability of a facility's equipment.
A common metric is taking the total maintenance cost (MC) as a percentage of the estimated plant replacement value (PRV).
If you want to take proactive steps towards maintenance and you have enough data to analyze, you can benefit from hiring a reliability engineer.
Implementing a stellar asset life cycle management program requires alignment with your business strategy, data-driven decisions, and the right culture.
All continuous improvement programs and computerized maintenance systems strive for the common goal of reducing this waste as much as possible.
An asset is any item that has potential or actual value to the company. Asset management is an approach to achieve the most asset value.
More people on maintenance staff doesn't necessarily reduce problems. In fact, it creates another kind of problem in terms of ineffective resource use
To get the very most out of your MRO (maintenance, reliability, and operations) inventory, you need to track data that reflects costs, turnover, etc.
Infrared analysis is actually super useful for checking temperatures, especially when you're comparing the temperature of an asset to another asset.
While RCM seems simple on its face, there are a huge number of moving parts within any solid reliability-centered maintenance plan that could go wrong.
Begin by checking the OEM manual. This will typically provide you with preventive maintenance guidelines. dffdadfdsfasdfasdfasdf
In order to track asset depreciation, you'll use its annual depreciation. The formula is (Initial Cost - Salvage Value) ÷ Useful Life = Annual Depreciation.
Selecting machines for preventive maintenance is a matter of finding which ones would benefit most from PM while keeping maintenance costs down.
A CMMS is a great way to organize user manuals and warranties by asset. Upload them and they’re ready to view by anyone with access.
The exact answer depends on your experience level, industry, and certifications. But the average wage for a reliability engineer is about $35 per hour.
We've compiled every type of food and beverage processing equipment out there in a list with everything you need to know.
A standard operating procedure, or SOP, is a document that lays out the steps to do something in a clear and concise way.
Implementing standard operating procedures (SOPs) may be a challenge. In this article, we’ll discuss various aspects of how to tackle this challenge.
Without effective maintenance process mapping, an organization will never achieve stable maintenance processes. Learn what you need to know here.
Root cause analysis (RCA) is key to a successful maintenance program. But to conduct one effectively, it’s critical to understand the components required.