Reliability Centered Maintenance (RCM) for multiple plants

With the support of MaxGrip, risk-based maintenance has become an important strategic pillar in one of the world’s leading dairy companies quest to control risks and optimize performance. Most Dutch production facilities have now adopted Optimizer+ and a maintenance blueprint that facilitates continuous improvement. This company employs more than 22,000 people and sells products in over 100 countries. Great opportunities are presented by the worldwide reputation of Dutch dairy, the growing demand for sustainable food, and the recent withdrawal of EU milk quota. With its future strategy as the main guideline, the company is preparing for global growth.

RCM

MaxGrip is this company’s partner for maintenance improvement. Since 2006, we have helped to improve the maintenance maturity of dozens of plants. We introduced Reliability Centered Maintenance (RCM) as the way to develop and optimize the company’s maintenance strategies. Rational simplicity is the key. Today the company has an extensive central database of RCM studies. Maintenance plans with proven track records have been implemented, resulting in steady progress across production locations.

Optimizer+

The accurate entry and processing of all asset data is vital in a process of continuous improvement. The company’s SAP EAM system, complemented and bolstered by our Optimizer+ software, is the foundation for its asset management framework. “With that system and the maintenance philosophy firmly in place, we can continue to make valuable contributions”, says MaxGrip maintenance consultant Siebrand Weening. “Optimizer+ keeps revealing new opportunities. For example, when the company wanted significant operational expenditure reductions in nine cheese plants, we were able to optimize the maintenance strategies and reduce costs significantly while complying with all risk control and performance goals.”

Benefits

How we help

  • Realising significant cost savings. Investing in RCM typically pays for itself at least sevenfold on a yearly basis
  • Committing to results and getting things done in the best possible manner for multiple sites
  • Connecting all dots between data and assets, solutions and best practices, people and systems
  • Creating companywide risk awareness, asset responsibility, and problem ownership
  • Improving maintenance and asset performance while reducing risks. RCM typically yields a productivity improvement of 3%, and spare parts cost reductions up to 30%
  • Embedding Optimizer+ and risk-based maintenance in a process of continuous improvement

The right balance

Effective RCM adds value by finding the right balance between asset performance, risks and costs. The process starts with determining which risks are acceptable and which are not. The company’s cheese plants mostly use the same equipment, but local maintenance budgets vary widely. “It is now part of the company culture to systematically compare and jointly examine the costs, risks, and potential for asset performance improvement. Data analysis reveals the differences, the exact number and nature of equipment failures, and the best practices in dealing with them.”

Committed to control

Achieving cost reductions is never difficult in itself. After all, simply cutting back on maintenance work and waiting to see what will happen is an option that will save money in the short run. MaxGrip works on long-term coherence between business goals, maintenance philosophy, risk reduction, and total cost of ownership. We are committed to control, and the company is able to reduce complexity while safeguarding continuous improvement without any compromise to (food) safety, quality, and the company goals and values.