Stage 1: FMECA and data baseline
As always, we started out with reviewing the current setup based on the documentation, data and procedures. We performed a Failure Mode Effect and Criticality Analysis (FMECA) for the equipment of four facilities as the other six facilities were already analyzed by the company to review key challenges and differences between the plants and distinguish all assets into separate risk categories.
Stage 2:PM/ PdM Program
Based on the FMECA validation workshops and based on MaxGrip’s best practices we developed the Preventive Maintenance and Predictive Maintenance (PM/PdM) Program. The consultants developed a failure mechanism reference library. Critical equipment with a high or significant risk to the performance and productivity of the plants received the most robust PM/ PdM package identifying failures before they arise. Assets with a medium risk’s measures were focused on the common predictable or age-related failures. Additionally, low risk assets would default to a minimum care package. In total 40,000 tags were in-scope which were covered by 2,804 task instructions.
For all of these maintenance tasks, MaxGrip provided detailed, long-text work instructions, aligned to the detailed component and failure mechanism. This detailed way of working was possible due to MaxGrip’s long track record and practice leadership. Focus was on non-invasive maintenance tasks to promote a proactive maintenance approach and take the first step in Digital Transformation, online asset condition monitoring and predictive maintenance.
We validated the maintenance strategy and packages with relevant stakeholders and facility maintenance teams.
Stage 3: deployment preparation
With the new strategy in mind, we created a practical spare parts management strategy with a focus on spares for assets which are production-critical and cost-savings on non-essential equipments by stocking spares minimally or not at all.
In this final stage of the project we also prepared the risk-based maintenance strategy for upload to the CMMS system. In that way, the IT provider could easily deploy the templates and operationalize the new fleet-wide maintenance plan.