The global leading producer of food ingredients wanted to optimize the way of working and increase the maturity level of the maintenance department. The production location produces 12.000MT of food ingredients yearly. They hired MaxGrip to perform an Asset Improvement Mapping (AIM), propose and deploy a global APM program for asset performance improvements.
The production site needed to uplift productivity to be able to fulfill the increasing market demands and to pick up production from the closure of another site. At the same time, maintenance cost had to be kept in control and would have to become predictable without restrictions on productivity, safety and compliance.
Christian Tinajero, Vice President Americas
The current situation of the plant was mapped out with an Asset Improvement Mapping (AIM). The findings were analyzed and a new way forward was proposed with a global APM program that includes a tailored roadmap, setting KPIs and target reporting through dashboards. The next stage was a limited scale deployment of the roadmap to carry out first fixes and a series of improvements based on the people, processes and technology dimensions.
Elimination of technical breakdowns by implementing a practical failure analysis process with trigger points in line with site objectives.
Maintenance cost control in place with usage of integer digital data structure reflecting the current asset situation on site (APM 4.0).
The professionalization of the maintenance organization resulted in improved quality of work, effective and efficient collaboration with the production team and increased skill level of technicians. In addition, production loss (both volume and quality) due to technical failures was eliminated. The company’s standardized way of working was embedded using their global maintenance blueprint. This ensured that best practices with quantified results could be shared internally on a global scale.
MaxGrip will soon start with the second phase of the APM Plan to further optimize production and way of working. MaxGrip was also asked to deploy the Asset Improvement Program at a second production location to broaden the success within the multinational.