Background
The degree of automation and the increasing tendency towards linking assets have led to growing demands on safety issues, environmental protection, quality and integrity assurance and product liability. In the chemical and energy sectors, companies are striving to maximise asset availability on a continual and sustainable basis. While their aim is to generate above average revenues, they also face other infrastructure challenges. Competition in the chemical industry is so high that companies not only need to safeguard themselves against shutdowns but also face the need to increase production output.
Manufacturing companies across industries are also faced with the challenge to improve plant efficiency in order to gain the competitive edge. In light of this, precise definitions of core competencies combined with the right organisational procedures and optimal, technical processes are essential to reduce costs and improve ROI.
Implementing cost, time and quality advantages These aims can be achieved using the methodology of Asset Performance Management (APM). APM takes a holistic approach to the optimisation of organisational and technical processes with the aim of achieving sustainable productivity gains. It is imperative to ensure the highest possible asset availability at the optimal cost-benefit ratio. The level of Overall Equipment Effectiveness (OEE) is one important performance indicator. APM facilitates compliance with relevant legal and regulatory requirements. Significant factors of APM are to increase efficiency and implement cost, time and quality advantages. Both technical and organisational processes are focal points of the optimisation.
To accompany management through this change process, our consultants can provide the following services according to individual requirements:
• Productivity analyses to optimise work cycles and processes.
• Best practice investment and maintenance strategies optimised to minimise risks
• Optimisation and creation of business models to improve cooperation with contractors and partners
• Execution of audits and the implementation of maintenance, storekeeping and equipment strategies
• Introduction of SAP PM and specific SAP consulting solutions
How a project is organised also plays a significant role in terms of performance enhancement. As well as assets, workflow must be optimised too. Ideas related to the project often arise during day-to-day operations but due to a lack of time and resources are not examined further or properly evaluated. It is crucial that projects are well-structured and fully realised to ensure optimal results. Companies can achieve growth in productivity of 15-25% by adjusting just a few specific processes.
Target: ROI of 2:1 to 5:1
Of utmost importance to sustainable productivity enhancement is optimal interaction between proactive management, strategic, action-oriented management systems and efficient assembly and work processes.
Three steps need to be taken to achieve these aims: firstly, an initial analysis and evaluation must be carried out, followed by project design and implementation and subsequently a final audit. From the very beginning of every project our aim is to achieve sustainable productivity improvement and a Return on Investment (ROI) of between 2:1 and 5:1.
Raising Staff Awareness
How does that actually work out in practice? One example: a chemical manufacturer with 200 employees and seven production lines wants to increase OEE by 5% and eliminate downtimes, production losses and other waste. T.A. Cook was responsible for the whole change and project management and immediately began to work with the maintenance staff to increase awareness of OEE.
By applying APM techniques and implementing various measures, the chemical company increased OEE for each production line by 5-8%. Further cost-savings of 2.5 million US dollars were also realised.
By increasing staff awareness, response times between machine breakdowns and repairs were halved from 45 to 20 minutes. Set-up times sank by one third and in one utility even by two thirds. The amount of time spent on preventative maintenance decreased too by 30%.
The entire project was completed in just 14 months – in time and in budget.
For more information contact:
Rupert Clark
Marketing Manager
Direct: +44 (0) 1183 260 229
Mobile: +44 (0) 7792 926 696
r.clark@tacook.com |
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