Victrex is a supplier of high-performance polymer solutions and is headquartered in the United Kingdom. Its manufacturing plants are located globally, in the United Kingdom, USA and China, serving customers across the globe. Victrex produces polymers, forms and parts for markets such as aerospace, automotive, electronics, energy (including manufacturing and engineering), electronics and energy. Victrex teamed up with MaxGrip to improve their asset management through a maintenance and engineering excellence program. As part of that program, MaxGrip assists Victrex with the implementation of their new EAM system, Ultimo.
Ambitions: New EAM System to Support Maintenance Excellence
The Senior Management team at Victrex aimed to enhance the overall performance of their assets as well as to support their Environment, Social, and Governance (ESG) objectives. The strategy for managing these assets was designed to include increasing production volume and quality, minimizing waste and energy usage, and providing the capability to oversee and measure performance throughout all locations, all while maintaining strict adherence to Health, Safety, and Environmental (HSE) standards. One component of this strategy specifically addresses the maintenance and engineering organization, their contribution to the company objectives and the ability to perform.
Victrex enlisted MaxGrip to assist in implementing their Maintenance Excellence Program. MaxGrip's methodology included an initial assessment of the current state and maturity level (termed Asset Improvement Mapping), which led to the creation of a strategic improvement roadmap. Following this, the Asset Improvement Deployment phase was initiated, comprising six distinct improvement workstreams, one of which is the CMMS/EAM.
The CMMS/EAM workstream is dedicated to adopting a better, unified Enterprise Asset Management system. Victrex recognized that lasting improvements would require an EAM system capable of supporting all maintenance excellence objectives. The new EAM system would have to be implemented while not disrupting ongoing production.
Approach: Structured Implementation
For the implementation of the Ultimo system at Victrex, MaxGrip's approach was structured to align with the client's specific requirements and overarching business objectives. Several important factors contributed to the successful implementation. To name a few: MaxGrip was already involved in the Maintenance Excellence Program and so was familiar with the Victrex organisation. The MaxGrip experience with Asset Management allowed the team to make best use of the flexibility of the Ultimo software. The solution had to contribute to the standardisation of the operations and effective cross-functional collaboration This streamlines system integration, reduces complexity and increases efficiency with features like automated workflows and enhanced reporting capabilities.
Below is MaxGrip's structured approach explained per stage.
Approach and Bluepint
The project began with thorough preparation, including a kick-off meeting and the installation of the EAM system. The initial phase involved setting up the project management, the start of (change) communication and preparing and facilitating workshops. MaxGrip asset management and implementation experts led these workshop sessions to share best practice use of the system with Victrex key users and other important stakeholders. The multidisciplinary sessions were focused on different themes, including:
- Asset Management
- Master Data Management
- Work Order Management
- Preventive Maintenance
- Stock & Purchase Management
- Mobile Usage
- Reporting
The workshop outcomes of system needs were the foundation for the roll-out blueprint, also developing a common data taxonomy and defining clear business processes to ensure a holistic and effective implementation at Victrex. The Victrex team was highly involved in the blueprint phase, another important success factor. The blueprint was applied in the next phase of Build and Realisation.
Build and Realization
During this implementation stage, the modules were configured as defined in the blueprint. The Victrex team prepared and populated data sheets with master data which were converted and imported to Ultimo by MaxGrip. Additionally, the team integrated other systems with Ultimo – for example to easily connect with Procurement. Meanwhile, key users were going through Ultimo's e-learning and a following key-user training on site through MaxGrip, which was tailored to the situation and needs of Victrex.
User Acceptance Test
At this pivotal point in the process, the system was completely configured to the specifications of Victrex. Their key users performed the User Acceptance Testing which was carried out successfully ensuring that the EAM system met all functional and operational requirements.
Stabilise
The final Stabilise phase focused on optimising the system through adjustments to the configuration, end-user training, and dedicated aftercare support to ensure seamless adoption and sustained performance.
Benefits: Set Up for Success
All five Victrex sites in the UK are now working with Ultimo as their EAM system. A Site in China will follow soon.
- Enhanced Decision-Making: With robust analytics and reporting capabilities, the new EAM system provides insights (through dashboards) into asset performance, maintenance costs, and operational efficiencies. This will make it possible for Victrex to make better informed decisions.
- Increased Operational Efficiency: Ultimo streamlines and automates many aspects of asset management, from work order management to inventory control. This reduces manual tasks, minimizes human errors, and accelerates response times, ultimately leading to improved operational efficiency.
- Standardisation: All sites will work in the same system, making standardisation possible. With the same way of working it's easy to benefit from each other's best practices and learnings. In the end, this will improve efficiency and efficacy.
- User adoption: with the structured process of implementation that MaxGrip has applied, the Victrex site teams were able to work in the system from the start. This improved user adoption and made the transition to the new system run smoothly.
As is explained above, the implementation of Ultimo is a significant workstream for Victrex to realie their Maintenance Excellence Program. The program will result in an overall and sustainable performance improvement, not only reducing cost but also improving reliability and therefore reducing cost of energy and waste. The implementation supports the benefits of the other workstreams, summing up:
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