Do You Really Need a CMMS? When Spreadsheets Aren’t Enough

The most dangerous thing about spreadsheets isn’t a misplaced formula or a corrupted file. It’s the knowledge trapped inside the heads of the people using them. Amanda Ortiz, a training and development professional with Atlas Roofing, warns of a ticking time bomb most businesses don’t even see. “Look at the numerous companies with management who have been with the companies for 30 to 40 years, and the only history of [preventive maintenance] or work done on machines are in the brains of the people retiring,” she said.

So, while some maintenance leaders may be lured in by the free nature of a spreadsheet, expert insights truly reveal the high cost organizations can pay by not advancing to a computerized maintenance management system (CMMS). Here we’ll take a thorough dive into the downsides of sticking with a spreadsheet maintenance management system (S-MMS), key signals that it’s time to make a CMMS shift and how Coast can help you move on to a more proactive solution.

The Spreadsheet Maintenance Management System (S-MMS): A House of Cards

The list of shortcomings is a long one when it comes to using an S-MMS. Here’s a look at some of the most glaring and impactful concerns:

• Lack of real-time data: How can you make informed decisions when you’re not informed? Since spreadsheets don’t automatically update across users or systems, your data might be outdated. Maintenance teams are at their best when they can rely on current data to make decisions. Without real-time visibility, delays and miscommunication are practically a given.
• Poor collaboration: When various people access and edit a spreadsheet, version conflicts and accidental overwrites can be everyday occurrences. An S-MMS lacks built-in workflows or user permissions, so tracking who changed what — and when — is a mission impossible, leading to chaos and lack of accountability.
• No historical context: Spreadsheets just aren’t designed to keep long-term asset histories or maintenance logs in an organized fashion. Because of that, recognizing recurring concerns, studying performance trends and strategizing preventive maintenance become manual and error-prone undertakings.
• Manual errors: Human error is simply unavoidable in spreadsheet-based systems, from small typos to incorrect formulas. These errors may sound on the harmless side but can domino into bigger consequences. We’re talking missed inspections, unplanned downtime and even safety risks.
• Reporting nightmares: Creating reports from spreadsheets is a time-consuming task that frequently includes cutting and pasting data, making charts manually and double-checking for errors and inconsistencies. And the lack of automation makes it very challenging to reach actionable insights without involving a dedicated analyst.

The True Cost of ‘Free’: Why Spreadsheets Are Wasting Your Money

While some may tout the benefit of spreadsheets being a “free” resource, sticking with this outdated tool may be a decision you end up paying for greatly. In fact, the relatively low cost of CMMS software looks like even more of a bargain when examining the many negative impacts on your bottom line spreadsheet reliance can inflict. These can include:

• Lost technician time: Maintenance technicians often devote valuable time (that could be used for actual maintenance work) manually entering data into spreadsheets. This inefficiency inflates labor costs and slows repairs. A digital system streamlines updates, enabling technicians to focus on important real work.
• Increased downtime: Spreadsheets make it hard to plan preventive maintenance as they lack automated updates. The resulting reactive approach means more unexpected equipment issues and costly downtime. Preventive maintenance software minimizes these concerns by scheduling timely service and more-informed resource allocation.
• Poor asset lifecycle management: Without the consolidated maintenance history, determining an asset’s true condition is a guessing game. Spreadsheets frequently fall short on highlighting recurring issues and usage patterns, resulting in premature replacements. This shortens asset lifespan and grows unnecessary capital spending on asset lifecycle management. 
• Unjustified MRO costs: Spreadsheets don’t provide the real-time inventory tracking that a CMMS does, resulting in over-ordering, stockouts and substantial wasted funds. Technicians may reorder unneeded parts or use time and energy having to scramble during crises. This lack of timely visibility elevates your maintenance, repair and overhaul (MRO) expenses, sometimes greatly. 

Signs It’s Time to Move Beyond Spreadsheets

If you’re a spreadsheet user who’s wondering if it’s time for a change, here are a few red flags that probably indicate the day has come to elevate your maintenance management with a CMMS. Do any of these indicators sound a bit too familiar? 

Multiple versions of the same spreadsheet float around.

Version control often turns to chaos when spreadsheets are emailed, downloaded and/or revised by various team members. Outdated data and costly errors from working off the wrong file are just part of the fallout. 

You see lost, forgotten or double-assigned work orders.

Without the built-in alerts, task tracking and user accountability of a CMMS, it’s easy for work orders to slip through the cracks or to be assigned to multiple people. 

You can’t easily tell what pieces of equipment received maintenance.

Spreadsheets just don’t provide the real-time maintenance chronicling or searchable records. Tracking past repairs, inspections or part replacements becomes a tedious time-waster. It also makes it difficult to identify patterns or strategize effective preventive maintenance. 

Audits and inspections feel like a scramble for documentation.

When compliance checks arise, searching through spreadsheets for details like proof of service, dates and signatures is a frenzied undertaking. A centralized system ensures you’re audit-ready by streamlining and concentrating reporting data.

You constantly put out fires instead of prevent them.

Because spreadsheets are reactive tools, they can’t foresee problems or trigger preventive tasks. Lacking automation and analytics — and the proactive maintenance planning tied to them — maintenance managers are mired in a repeated cycle of emergency fixes.  

Ortiz adds another common sign: “When a machine goes down, and you had no idea this was happening.”

She asks, “Maybe your PMs are noted on a spreadsheet or remembered by someone, but do you have any record of the inspection of a particularly expensive piece of equipment? Can you see your top 10 assets that have costed you the most from downtime, and are you able to make sure you have all critical parts on hand? These are important pieces a CMMS takes care of. The biggest red flag would be when a critical piece of equipment breaks down and people are panicking to get the parts needed.”

From Reactive to Proactive: How a CMMS Changes the Game

Maintenance management should have a solid foundation to it, but a spreadsheet is far more like a house of cards waiting to fall. Take control of a proactive strategy through  CMMS implementation — and remove the guesswork and reactive strategies that only serve to hurt your bottom line. 

Here’s a quick overview of the key upgrades a CMMS brings to the maintenance table that a spreadsheet simply can’t deliver:  

• Centralized data: Store comprehensive asset details, service history and maintenance records in one place, boosting team-wide visibility and eliminating scattered spreadsheets.
• Automated work orders: Produced, assign and follow work orders automatically, reducing manual entry errors and making sure tasks are done in a timely fashion. 
• Preventive maintenance scheduling: Time interims or usage metrics prompt PMs, assisting breakdown prevention and prolonging equipment lifespans. 
• Asset management: Better-informed budgeting and planning are the key benefits of tracking each asset’s lifecycle from purchase to disposal. This includes their maintenance costs, depreciation and performance trends. 
• Mobile access: Work order apps make it easy to update and complete work orders on the go, improving response times and curtailing tedious paperwork. 

Looking to the Future: A CMMS Keeps You Ahead of the Game

To CMMS expert Ortiz, the improvements provided by a CMMS’s dynamic tools are too vital to pass up for managers looking to stay ahead of the game. “A CMMS provides visibility throughout the company — a place to keep all history of work requests, work orders, equipment, parts — and the ability to assign roles to certain people. So, it’s not a bunch of people just updating a spreadsheet,” she explained. 

“With the documented history of work done on assets, it is so much easier to keep track of trends and data, which shows you how often a machine will break down,” Ortiz remarks on this vital benefit of a CMMS. “It is not always predicted, but if it isn’t, you will at least have a bill of materials in the system, which will allow you to have parts on hand at all times. The CMMS can also identify which pieces of machinery you need to watch closely when doing a daily walkthrough or preventive maintenance. A lot of times this is not documented correctly on a spreadsheet.”

How Coast Helps You Break Free From the Spreadsheet Cycle

While there are other CMMS resources out there, more than 10,000 teams rely on Coast every day. Here are just four ways that Coast elevates your maintenance management that spreadsheets can’t even approach:

• Easy work order management: Coast empowers maintenance teams to produce, assign and oversee work orders in mere seconds. Boosted by real-time updates and alerts, tasks stay on track seamlessly, reducing delays and miscommunication across maintenance operations.
• Asset history and inventory: Every asset’s maintenance history, parts usage and their associated expenses are automatically recorded, giving teams complete visibility into performance trends, repair frequency and inventory needs. 
• Checklists and SOPs: With standard operating procedures (SOPs) and task checklists stored digitally, consistency and accountability are guaranteed. Technicians can follow clear step-by-step guidance, lowering errors and elevating compliance with safety and quality benchmarks.
• Intuitive mobile app: Coast’s mobile app boasts a clean, user-friendly interface that technicians can quickly master. It simplifies updates, work order tracking, and asset lookup — which makes for a smooth adoption across your team.

Why It’s Time to Upgrade Your Maintenance Strategy

There’s no time like the present to invest in the efficiency, reliability and peace of mind that a CMMS provides. Spreadsheets are a short-term solution that can cost your organization dearly in the long-term. 

In today’s data-driven world, relying on spreadsheets for maintenance management is like using a kid’s tin-can telephone in the age of smartphones. A CMMS provides the intelligence, automation and scalability that modern operations demand, empowering teams to make proactive decisions, reduce downtime and extend asset life — all while centralizing data and streamlining workflows. 

But the shift isn’t merely about upgrading tools, it’s about transforming maintenance into a true strategic advantage. For organizations aiming to stay competitive, efficient and future-ready, the upgrade to a CMMS isn’t a luxury — it’s a necessity. And the time to evolve is now.