Case Study for Planned Maintenance Implementation

It has, for some years been realised that prevention is better than cure and that proactive, rather than reactive, management brings far and away the best results for businesses. This is true for managing human resources, change policies and, just as importantly, for managing the machinery that all manufacturers use to produce their products.

All machines require regular and effective planned maintenance to operate correctly and meet their design specifications. The consequences of ineffective planned maintenance can be huge in terms of factory profitability, personnel moral and management time.

Such consequences are often overlooked or mis-calculated because machine breakdowns (almost always caused directly or indirectly by ineffective maintenance) are not just a cause of lost time and potentially missed deadlines but have a direct effect on factory throughput, efficiency and thus profitability. Therefore, the importance of effective planned maintenance to reduce the occurrence of such incidents cannot be understated.:

Case Study - Newspaper Printing Industry - Leicester

Situation Prior to planned maintenance Implementation:

Older, existing CMMS package unused, disregarded and generally discredited
Resulting in reactive breakdown response environment
Little or no planned maintenance
No engineering resources control
No control of contractor work or costs
No history of work and costs on assets
No definition of critical assets to focus effort and assist in quality system operation
No tie in with stores system

Action Taken

Phased planned maintenance implementation carried out to meet budgetary constraints
Introduction of concepts to key and associated personnel
Administration roles identified and rigorous training carried out for individuals concerned
'Scoping Phase' work carried out to identify assets and all associated information
Successful 'Planned Maintenance Implementation Phase' to write and schedule detailed planned maintenance tasks completed
Planned Maintenance Implementation Phase expanded to remaining operations and services
Support contracts arranged to instigate and monitor Continuous Improvement initiatives

Results

Improvements shown for all Key Indicators

Downtime reduced by 400%

Results of Planned Maintenance Implementation

Additional engineering resource requirement identified

Resource result of Planned Maintenance Implementation

Current resource focused on critical assets
Resource utilised to best company advantage
All required proactive maintenance (including contractor support) now planned around 'Windows of Maintenance Opportunity'

AB Mauri UK & Ireland

Able Breads
ABR Foods
Aircelle (SAFRAN Group)
Airflow Streamlines Ltd.
Alcan
Alcoa
Alcoa CSI UK Ltd.
Allied Bakeries 8 UK Sites
An Post 4 Sites
Apollo Fire Detectors
Artex Blue Hawk Ltd.
Artex Rawplug
Askeys Ltd.
Associated Creameries
B&Q Plc.
B&W Loudspeakers
Baker Group of Companies
Baxenden Chemicals Ltd.
BCA
Bendicks (Mayfair)
Bostik 2 Sites
Bottle Green Drinks Co.
Braces Bakery 2 Sites
Bredero Shaw
Bristol Airport
Bristol Bending Services
British American Tobacco
Bryan Donkin Ltd.
Buckingham Foods
Burlington Slate
Burn Stewart Distillers Ltd.
Calsonic Climate Control Ltd.
Cereform Ltd.
Charnwood Foods
Chevron Texaco - East Midlands Airport
Cisco Systems Int BV.
Cisco Systems UK, Europe & Middle East
City Industrial Waste
Classic Courverture
Coates Electrographics
Coates Electrographics USA
College Gwent
Constellation Europe
Couldron Foods
County Confectionery
Coutts Packaging
DAC Plant
Dairy Crest Haverfordwest
Dalgety Arable
Dartington Foods Plc
Delphi Diesel Systems
Dorset Chilled Foods
Dove Valley Ltd.
Dovecote Park
Dowty Engineered Seals
Ducal Ltd.
Eaton Aerospace
Eaton Hydraulics
Economatics (Industrial) Ltd.
Edinburgh City Council
Edrington Group 5 UK Sites
Element Six Production Ltd.
Elizabeth Shaw Ltd.
Encase Holding Ltd.
Encase Northern
Environmental Agency
Eternit
Euramax
Euro / DPC
Evode Ltd.
Exitech Ltd.
Explore Manufacturing
ExxonMobil 110 Sites Globally
Fenmarc Produce Ltd.
FFP Packaging Ltd.
Field Packaging Ltd.
Fortnum & Mason
Frank Wright Ltd.
Fusion Provida
Games Workshop
Gatwick Airport - Shell Aviation
GEO Adams & Co
GKN Driveshafts
GKN Hardy Spicer
The Cheese Company 4 Sites
GPS UK Ltd.
Grace Construction Products Ltd.
Greene King Brewing & Retailing
Greenway Lubricants Ltd.
Gulf News - Dubai 2 Sites
Hammonds Furniture Ltd.
Hazlewood Chilled Meals
Hazlewood Food Enterprises
Heathrow Airport - H.H.Op. Co.
Heraeus Electro-Nite
Hygrade Foods 2 UK Sites
Iceland Frozen Foods Plc
ID Data Systems Ltd.
Impact Control Systems Ltd.
J&A International
Johnson Controls
Kalmar
Kerry Aptunion
Kerry Foods 2 Sites
Kerry Ingredients
Kerrygold Company Ltd.
La Fornaia
Lafarge Lime
Lanstar Ltd.
Lawson Mardon Packaging
Lawson Mardon Star
Leicester Fire & Rescue Service
LG Philips
Linpac Storage Systems
Linread Automotive Plc.
Lion Foods Ltd.
Magners
Manor Bakeries Ltd.
Marchwood Power Ltd.
McCormick Group 2 UK Sites
Microvue Ltd.
Midland Meat Packers
Mixalloy Ltd.
Moss Plastic Parts Ltd.
Mowlem Technical Services
New Covent Garden Soup Co.
New Milton Sand & Ballast
Northern Foods
Norwich Corrugated Board Ltd 2 UK Sites
Novartis Consumer Health
On-Site Central Ltd.
Paarman Foods - South Africa
Pann Krisp
Parcelforce Coventry Hub
Parrs Confectionery
Paula Rosa Kitchens
Peartree Foods
Permabond
Permadoor
Peters Food Service
Plastic Omnium Automotive Ltd.
Plastics Manchester Ltd.
Polycast Ltd.
Poly-Flex Circuits Ltd.
Polyframe Trade
Poole Harbour Commissioners
Pork Farms Bowyers Ltd.
Pritex Ltd.
PVI Ltd.
Raven Manufacturing Ltd.
Regent GM Laboratories
Reichold UK Ltd.
REW Acton Ltd.
Relyon Ltd.
Richard Burbage Ltd.
Ricon Ltd.
RMH - Avana Bakeries
Roltech ASD.
Royal Doulton (UK) Ltd.
Royal Mail Group
S.A.T.O. (Greece)
S.H. Agricultural Engineers
SCA Packaging Ltd.
Scottish Power
Sekisui (UK) Ltd.
Shanks Chemical Services
Sheffield Care Trust
SIFE Unigate France
Sigma Aerospace Ltd.

Smart Systems
Sola Optical (UK) Ltd.
Solo Europe
Spirax Sarco
St. Ivel Ltd.
Stansted Airport - Stansted Fuelling Co.
Stansted Airport - Stansted Into Plane Ltd.
Stanton Plc.
Steetley Dolomite
Still Material Handling Ltd.
T&B Group UK and Europe
Tarmac Topblock Ltd. 2 Sites
Telford Extrusions Ltd.
Telford Foods Ltd.
Harmsworth Press 11 Sites
The Royal Free Hospital
The Royal Mail
Thompson Plastics Group
Tangerine Confectionery 6 Sites
Tornado Pty
Trans World International
TRW Lucas Varity
Tuberex Ltd.
Tucker Fasteners
Tulip UK Ltd. 17 Sites
Tyco
UK AEA Jet Facility
Unigate Dairies Ltd.
Unigate EFG Plc UK and Europe
United Utilities Industrial
UYT
Vibro Meter
Vickers Industrial Products
Vickers Systems
Viking UK Gas
Viridor Waste Management 69 Sites
Visqueen Building Products
VP Automation
W.A. Turner
Watlow Ltd.
WBB Minerals
Whitworth Bros.
Wincanton Logistics
Winkhaus (UK) Ltd.
Woodbridge Foam 3 European Sites
Xyratex
Yoplait Dairy Crest

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