Maintenance and Reliability Case Studies and Bench-marking Data

Maintenance and Reliability Case Studies and Bench-marking Data

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  Copyright 2009 GPAllied©
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  Best Practice Benchmarking “BestPractice Plants have Best Practice Behaviors and those behaviors drive Best Practice Results” • Focused on 35 Companies that have known corporate reliability initiatives in 8 verticals – Automotive, Chemical Processing, Food & Beverage, Metals & Mining, Petro-Chemical, Pharmaceutical, Power C Generation/Transmission Pulp & Paper • Focused on 35 Best Practice Elements Across 4 Primary Areas – Leadership – Work Management – Reliability Engineering – Asset Health Management g • Results represent performance at 633 sites in over 20 countries • Additional 250 sites in overall database Copyright 2009 GPAllied©
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  Best Practice Benchmarking “I could agree with you, but then we’d both be wrong” 1. Chemical Processing 522 2. Petro-Chem 498 3. 3 Pulp & Paper 468 4. Automotive 465 5. Pharmaceutical 431 6. Metals & Mining 430 7. Power 373 8. Food & Beverage 369 Copyright 2009 GPAllied©
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  Case Study Results PharmaceuticalsIndustry Ph ti l I d t • Prior to Reliability Initiative – Patented product going off patent • After Reliability Initiative y – Reactive Maintenance 71% 7% – Overtime 22% 5% – Maintenance Employees (FTEs) 350 250 – Added 9 Planners, 7 PdM Planners Technicians and 8 Reliability Engineers… Source: John Schultz Copyright 2009 GPAllied©
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  Case Study Results(continued) Pharmaceuticals Industry Ph ti l I d t • After Reliability Initiative – Availability increased 12% – Healthy Assets 35% y % 85% % – Production Deviations to 1/10th of previous levels – Maintenance Budget reduced 40% – Inventory reduced 33% – Insurance Premiums reduced 30% Source: John Schultz Copyright 2009 GPAllied©
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  Case Study Results- Steel Industry • Prior to Reliability Initiative y – On verge of bankruptcy • After Reliability Initiative – Reactive Maintenance 70% 20% – Availability 78% 91% (based on 8,760 hours) – Product Q lit (Yield) P d t Quality (Yi ld) 76% 91% – Inventory reduction of $40 million – Maintenance Costs reduction of 50% – Most P fit bl Steel Producer 1999 M t Profitable St l P d – Ranked as #1 Steel Maker in the World by Dow Jones Source: Dofasco Copyright 2009 GPAllied©
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  Case Study Results- Food Processing • Operational Asset Utilization increased 4% for each of 21 flourmills – Equivalent to adding an additional plant to the system – Significant savings also realized by not having to ship out of position Source: Copyright 2009 GPAllied©
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  Case Study Results- Food Processing • Two of a business unit’s largest food processing plants increased their OEE 9% in 4 years – Reduced maintenance spend by 28% p y – Reduced parts inventory by nearly 30% Source: Copyright 2009 GPAllied©
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  Case Study Results- Food Processing • Meat Processing – Doubled head/day production over the past 3 years – $45 million swing in P&L Source: Copyright 2009 GPAllied©
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  Case Study Results- Food Processing • European Food Oils – A business unit consisting of 16 plants dropped maintenance costs by 27% and improved RAV by 1.4% in 3 years – At the same time, realized a 20% increase in OEE Source: Copyright 2009 GPAllied©
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  Case Study Results- Salt • A facility has reduced Maintenance cost to RAV ratio by 3% over the last 3 years – Equates to $2 million maintenance cost savings from baseline year while increasing plant reliability – Facility had a history of missed shipments to key clients prior to initiative Source: Copyright 2009 GPAllied©
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  Case Study Results- Chemical Processing and Mining d Mi i • Increase OEE by nearly 30% in 2 years – 22% reduction in their annual maintenance expenditure – $15 million per year on the bottom line Source: Copyright 2009 GPAllied©
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  Case Study Results- Power Generation • Successfully extended time between planned turnarounds by 30% – Reduce time in turnaround by 20% – 23% reduction in maintenance costs Source: Copyright 2009 GPAllied©