It is critical to first establish if the current asset base can deliver the performance targets with the current budget allocation for asset care and maintenance. Our modeling process can establish if the targets can be met with the current budget and further, determine if the budget can be reduced and performance maintained. Once the model is in place, it can be a continual tool to justify budget amounts and make assessments of the impact on cost and performance with any budget cuts.
The high cost assets tend to be informally understood in most organizations but at times actual numbers are hard to come by, often in part due to the configuration and use of the EAM system. However, in terms of assessing budget spend and identifying areas for improvement, real data and communication of the assessment and approach is key.
Analyzing EAM system data to identify and generate easy to understand assessments is an important first step to support the assessment and review of maintenance plans for key assets. Current plans can be challenged and optimized with the support of any available data to ensure the most cost-effective tasks are in place and that budgets are defensible. To generate a completely defensible zero-based budget, we use a FMECA based assessment of your assets to develop cost justified tasks.
They are grouped into practical packages of work and deployed directly into your EAM system. The initial assessment sets the baseline for a dynamic budgeting and optimization process, driven by real data and site experience to fine tune costs and performance. An effective shutdown is not just about the outage being completed on-time and on-budget. Through a detailed assessment of asset care requirements and shut down task requirement, we challenge traditional shut intervals, optimize the interval and assess the likely impact on costs and performance of moving shutdown intervals.
A holistic asset strategy and performance improvement process, focused on achieving the optimal balance of risk, cost and Determine predicted availability for new equipment, or de-bottleneck existing operations, taking into consideration Identify and optimize critical spares holding levels to support operations at minimal cost and risk.
If there are too many steps or details listed, people will be unlikely to follow them all, so specify only important ones.
Optimize equipment: Understand how to leverage equipment and machines, to make the most of them. Review training practices: Make sure that work processes are designed for maximum safety, and maintenance personnel is properly trained. Implement training for existing equipment, as well as new machinery or parts. Safety first. Maintenance schedules: Not all breakdowns or repairs can be predicted, but preventive maintenance keeps them minimized.
Set up a regular maintenance schedule that covers all essential equipment and accessories. This gives you a buffer, cutting down the cost and time required for handling repairs, especially in emergencies. Make sure to call experts for critical repair and maintenance.
They can keep an eye or ear out for unusual noises, damage, and other issues. Train them to identify common failures or potential problems. The right technology: Using the right tools can improve the efficiency and productivity of your maintenance processes.
But how can you prevent breakdowns? Without a doubt, you should invest in a good preventive maintenance strategy and ideally in a CMMS or, even better, an Intelligent Maintenance Management Platform IMMP capable of scheduling, tracking and reviewing all technical operations.
If your average repair time is too high , one reason could be having a lack of spare parts in stock. Having the same parts fit many machines can be a smart money saving trick and makes it easier to obtain technical assistance from the manufacturer. Finally, you should bear in mind that ordering parts in bulk allows you can negotiate better prices. Another key to keeping maintenance costs down is training your entire team and not just the technicians.
If all of your employees know how to detect problems, malfunctions will be detected much faster.
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