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Background

Background The client is a utility company in the southern US. Their overall maintenance costs were exceeding budget allowances while equipment performance had not been improving . SPG ’ s Consulting Assignment

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Background

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  1. Background The client is a utility company in the southern US. Their overall maintenance costs were exceeding budget allowances while equipment performance had not been improving. SPG’s Consulting Assignment The client asked SPG, Inc. to help them improve transmission reliability while stabilizing costs. SPG - Business Analysis Findings SPG consultants catalogued all of the current preventive maintenance (PM) tasks, then assessed PM compliance and effectiveness. This identified the potential to significantly reduce the number of time-based PM tasks, while maintaining the same level of equipment performance. Results and Quantitative Benefits Installation of Planning & Scheduling increased maintenance work force productivity by 18%. Available maintenance hours redirected to predictive maintenance tasks. Daily maintenance schedules created and integrated into operations schedules. Maintenance crews able to generate work orders that addressed potential failure modes. Background The client is the largest facility of a Fortune 200 chemical company. SPG’s Consulting Assignment The program included asset productivity, planning and scheduling, contractor management and leadership development . SPG - Business Analysis Findings SPG consultants applied Reliability Centered Maintenance (RCM) on all critical equipment to identify immediate action items. Although this facility already had maintenance planners, they were ordering parts, completing permits and processing work orders. Results and Quantitative Benefits Maintenance planner position upgraded to include control of requested contract work. Planning and Scheduling (P&S) implemented. Underutilized capacity allowed non-critical work to be deferred and a significant amount of work to be brought back in-house. Ten “Maintenance-In-Action Learning Modules” for the Operations Leaders created to help them in “owning” their equipment. The benefits from the engagement totaled $5.6 million. Improving Business Performance through Enhancements in the Maintenance Function – Three Case Studies • Background • The client is a tire manufacturing company based in the US. • SPG’s Consulting Assignment • The client asked SPG, Inc. to help them with employee participation and continuous improvement . • SPG - Business Analysis Findings • SPG consultants identified that implementing Self-Directed Work Teams and the Five “Pillars” of Total Productive Maintenance (TPM) would improve overall performance. • Results and Quantitative Benefits • Safety record improved 129%. • Defects causing rework or waste were down 57%. • Productivity was up 11%. • Waste was down by 38%. Once implementation was underway, a migration plan was designed to move the process to the other eight plants in the Western Hemisphere. • Schrudder Performance Group, LLC. Proprietary Information – 1002

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