EAM G-150 aims to develop comprehensive Asset Care master data to facilitate the lifecycle management of newly installed equipment. Utilizing Actemium’s AIRO equipment reliability process, an analysis will be conducted to establish a physical hierarchy, component breakdown, Bill of Materials, and spare parts inventory. Stocking decisions and levels will be provided to the client. Additionally, Failure Modes and Effects Analysis (FMEA) will be performed to devise the necessary Preventive Maintenance (PM) program, ensuring equipment longevity and reliability. The analysis-derived data will be integrated into the client’s Computerized Maintenance Management System (CMMS).
CHALLENGE:
The customer upgraded their brewing capability with a significant investment in state-of-the-art brewing process equipment. An investment of this magnitude requires a comprehensive Reliability and PM program to ensure the equipment performs at the level required to achieve the business case that the project was built upon. Once completed, the deliverables will exceed the quality and integrity levels of their current data.
SOLUTION:
Utilizing the Actemium process, a comprehensive analysis was conducted to identify all essential data elements crucial for maximizing the equipment’s life cycle extension. OEM supplied documentation is the source of all input into the analysis process. The analysis’s output will give the customer a hierarchy of equipment to support their work management systems and processes. Spare parts associations to equipment, stocking decisions and suggested inventory levels will also be provided to the customer as a deliverable. In addition, the customer will be provided with an extensive list of required tasks that if executed promptly will protect against large comprehensive breakdowns and will improve the unplanned downtime that they will experience.
PROJECT TEAM:
Our Junior and Intermediate Reliability specialists conducted the analysis, with weekly status calls and assigned responsible persons for tracked action items. The project’s primary goal was to create and load master data into the customer’s Production system. Actemium and the customer collaborated in brainstorming sessions to address cutover challenges, ensuring no disruption to current functionality and minimizing end-user confusion.
RESULTS:
Actemium is delivering a lifecycle reliability program aimed at safeguarding the customer’s significant equipment investment. This is achieved through a combination of OEM recommended strategies and Actemium’s own FMEA analysis methodologies. The analysis conducted aims to reduce unplanned downtime by enhancing material availability and preventing catastrophic failures. Spare part stocking levels are typically 20% lower than OEM recommendations, resulting in immediate cost savings and freeing up cash previously tied up in inventory. The service aligns with the customer’s standards for Asset Care master data and has been consistently praised as “world-class” by the customer.
CONCLUSION:
Our service can enhance existing programs or establish new ones. Industries failing to meet targets in unplanned downtime and reliability could benefit from our approach. Medium to large manufacturing businesses typically utilize CMMS systems for data and maintenance processes. Optimizing inventory levels and timing preventive maintenance are crucial for optimal performance.
