The pharmaceutical client was suffering production losses through unplanned equipment failures and found themselves in a fire fighting environment in terms of maintenance activity.
Whist the focus on quality and compliance was high, the topic of asset management had not been addressed at the facility.
The company wanted to understand how they could identify the ‘quick wins’ needed to get performance back on track and to start eliminating defects along with ensuring a program is implemented for longer term sustainable asset management. It was agreed the first step was to perform a Reliability Maturity Assessment on an agreed defined list of target areas and determine what gaps currently existed between current and future desired state.
The Target areas agreed for the reliability maturity assessment:
- Plant Culture
- Engineering Strategy
- Defect Elimination
- Spares Parts Management
- Reliability in Operations
- Reliability in Design
- Maintenance Practices
The assessment was performed over 2 days and combined site and work area visits along with a timetable of selected interviews.
With the assessment complete and the gaps from the current state to the future desired state identified, a project plan was developed to address the key recommendations from the study.
The implementation of the recommendations from the assessment by utilising a well-defined project plan will support the organisation’s desire to reduce equipment failures and raise the profile of Asset Management with a key focus on Reliability.