The leading global 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 food 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.
Case study – highlights
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.
- Role separation for operations and maintenance teams, embedding clear roles and responsibilities and a new way of collaboration between the two teams;
- Personal development plans and hands-on coaching;
- Adding a dedicated planner & scheduler and reliability engineer with clear role separation resulting in optimal workforce efficiency.
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 (Industry 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.
OEE (overall equipment effectiveness) uplift 6%, which saves over €0.5 million YoY
28% reduction in breakdown cost (annually)
Average maintenance cost per WO reduction 19%
Planned Work Order throughput time improvement 66%, Reactive Work Order throughput time improvement 62%
Savings identified on Structural Failure Analysis R$ 2.1 M ($556K or €525K)
MaxGrip will continue with the second phase of the APM Plan to further optimize production processes 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.
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