Intelligent Predictive Maintenance and Service for large manufacturing plants across US and Canada
About Client
A global leader in architectural products and services specializing in design and development of metal and glass products and services for enclosing commercial buildings, displays, and framing art.
Case Context/Overview
- Client is undertaking a large SAP S/4HANA led transformation to improve manufacturing processes and associated through put.
- Key scope element included modernization of current maintenance and service-related processes and underlying technology across plants in US and Canada.
- To plan and schedule maintenance activity for production critical resources including key manufacturing assets.
- To guide the users on Breakdown, Preventive and Corrective maintenance activities resulting in reduction of downtime and cost of maintaining assets.
Key Solution Elements
- Understanding of current maintenance processes, pain areas, feasibility study through 'Discover' phase.
- Detailed representation of TO-BE processes and Gap analysis using BPMN and transaction/event chain diagrams in 'Prepar' phase.
- Build and demonstrate prototype during 'Explore' phase.
- Maintenance processes solution design, legacy data transfer, authorization controls, SIT in 'Realize' phase.
- Integrated cutover plan through ‘Deploy’ phase.
Scope of services
- Preventive Maintenance to keep assets in peak operating condition.
- Equipment repairs to initiate repairs and coordinate every step in a repair activities.
- Refurbishment to restore faulty parts to their operational status.
- Personnel Management (PA) to assign employees for work based on their skills.
- Capital maintenance to manage major repair of a machine or an equipment where asset value increases.
- Shutdown maintenance to capture maintenance related to planned shutdowns.
- Integration with Materials Management (MM) to manage spare or repairable parts.
- Leverage investments in sensors and associated data to develop predictive maintenance and services.
Benefits and Value Delivered
- Prevention of malfunctions.
- Increased availability of technical systems for manufacturing processes.
- Lower restart costs.
- Improved lifespan of production machineries.
- Integration with procurement and inventory processes enables clear tracking on MRO consumption for maintenance activities.
- Enhanced ability to track and optimize cost of the maintenance activities involved across equipments in the plants.
