case study client’s global asset management strategy ...€¦ · strategy starts with reliability...

Client’s global asset management strategy starts with Reliability Centered Maintenance (RCM) pilot CASE STUDY (1) Asset Cricality Assessment (2) Failure Mode & Effects Analysis (FMEA) The company was experiencing asset reliability issues on several coater lines, which are asset intensive and technical in nature. This was resulng in equipment availability and downme constraints, impacng their ability to hit producon targets. Our client is one of the world’s largest manufacturers of float, value-added and fabricated glass products and soluons. They have 25 float plants globally that produce high performance glass for architectural, residenal, interior, transportaon and technical applicaons. The company was looking to improve its’ asset strategies by implemenng Reliability Centered Maintenance (RCM) to improve reliability and availability of crical assets . IE was engaged to execute workshops in: APPROACH FINDINGS Copyright ©2019 Implementaon Engineers ● www.implementaon.com ● +(1) 312 474 6184 Root Cause analysis shines light on key issues driving underperformance in material supply Pilot Approach – IE began by developing tools, organizaonal awareness and training with the key stakeholders in order to develop and implement RCM processes and strategies to maintain crical assets on a key float line. This RCM model could then be replicated to the other areas of the plant and across the other plants around the globe. 1. 52% Percent of evaluated assets idenfied and added to the client asset registry By engaging with Implementaon Engineers on a Reliability Centered Maintenance pilot, our client has now rolled this process out globally. The results across the enterprise will be substanal in reducing downme and improving reliability of crical assets The RCM workshop was conducted on assets based on the results from the cricality analysis evaluang the top crical assets. The FMEA executed for the workshop idenfied maintenance strategies and developed the Equipment Maintenance Plans (EMP) based on failure modes and the risk criteria of: Severity, Occurrence, and Detecon; these criteria develop the overall Risk Priority Number (RPN). 3. 34% Failure modes evaluated with a high or crical ranking that were not being addressed 55% Reducon of the Risk Priority Number (RPN) based on the FMEA improvements The workshops were aended by key stakeholders from the sites and the corporate reliability group. Our client is now working on implemenng these processes and tools across the global enterprise. 4. The cricality workshops began with the fundamental elements that need to be addressed: Equipment Hierarchy and Equipment Data A total of 267 assets were evaluated during the cricality analysis The equipment hierarchy analysis revealed there were 140 assets not included in the current registry 2. Cricality ranking criteria was developed in the areas of: Safety, Environmental, Cost, and Producon.

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Client’s global asset management strategy starts with Reliability Centered Maintenance (RCM) pilot

CASE STUDY

(1) Asset Cri�cality Assessment (2) Failure Mode & Effects Analysis (FMEA)

The company was experiencing asset reliability issues on several coater lines, which are asset intensive and technical in nature.

This was resul�ng in equipment availability and down�me constraints, impac�ng their ability to hit produc�on targets.

Our client is one of the world’s largest manufacturers of float, value-added and fabricated glass products and solu�ons. They

have 25 float plants globally that produce high performance glass for architectural, residen�al, interior, transporta�on and

technical applica�ons.

The company was looking to improve its’ asset strategies by implemen�ng Reliability Centered Maintenance (RCM) to improve

reliability and availability of cri�cal assets . IE was engaged to execute workshops in:

Root Cause analysis shines light on key issues driving underperformance in material supply

Pilot Approach – IE began by developing tools, organiza�onal awareness and training with the key stakeholders in order to

develop and implement RCM processes and strategies to maintain cri�cal assets on a key float line. This RCM model could

then be replicated to the other areas of the plant and across the other plants around the globe.

52%Percent of evaluated

assets iden�fied and

added to the client asset

registry

By engaging with Implementa�on Engineers on a Reliability

Centered Maintenance pilot, our client has now rolled this process

out globally. The results across the enterprise will be substan�al in

reducing down�me and improving reliability of cri�cal assets

The RCM workshop was conducted on assets based on the results from the cri�cality analysis evalua�ng the top cri�cal

assets. The FMEA executed for the workshop iden�fied maintenance strategies and developed the Equipment Maintenance

Plans (EMP) based on failure modes and the risk criteria of: Severity, Occurrence, and Detec�on; these criteria develop the

overall Risk Priority Number (RPN).

34%Failure modes evaluated

with a high or cri�cal

ranking that were not

being addressed

55%Reduc�on of the Risk

Priority Number (RPN)

based on the FMEA

improvements

The workshops were a�ended by key stakeholders from the sites and the corporate reliability group. Our client is now

working on implemen�ng these processes and tools across the global enterprise.

The cri�cality workshops began with the fundamental elements that need to be addressed: Equipment Hierarchy and

Equipment Data A total of 267 assets were evaluated during the cri�cality analysis The equipment hierarchy analysis

revealed there were 140 assets not included in the current registry

Cri�cality ranking criteria was developed in the areas of: Safety, Environmental, Cost, and Produc�on.

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