Driving your targets

Transcription

1 Driving your targets

2 World-class Maintenance: Operation excellent

3 Maintenance activities ARE YOU ABLE TO FOLLOW THE RIGHT PRIORITY?

4 Maintenance strategy for reliability, productivity and efficiency WHEREVER YOU ARE, WE HELP YOU TO FIND THE RIGHT WAY FOR AN OPERATIONAL EXCELLENCE Maintenance Engineering and Organization Productivity and Efficiency Digitalization process Enterprise Asset Asset criticality Equipment tree Maintenance re-organization Maintenance assessment Process mapping People evaluation Change Productivity assessment Technical KPIs: (Mean Time Between Failures Mean Time To Repair) Costs analysis Productivity KPIs: Overall Equipment Effectiveness Down Time LCC Life Cycle Cost TCO Total Cost of Ownership Lean Manufacturing World Class Manufacturing Asset and IT infrastructure audit Network and server Infrastructure Cloud - hosting and housing in datacentre GDPR : General data protection regulation AT4assessment AT4safety AT4ticketing Best practices FMAEA/CA Failure Mode Effect analysis and Criticality analysis RBI Risk Based Inspection PdM Preventive Maintenance Plans Reliability & Availability RCFA Root Cause Failure Analysis Work instructions Condition monitoring & predictive ISO Environmental ISO Safety ISO Sustainability Quality, Safety & Environmental ISO 9001 Quality Quality assessment Risk assessment Safety Training and Coaching Warehouse assessment Safety Stock Warehouse Criticality analysis Warehouse and spare part Warehouse automation Stock out analysis Spare part standardization IN OUT warehouse

5 World-class Maintenance FRAMEWORK MAP Statistical analyses PM optimization L.C.C. World-class Maintenance Condition based Costs Spare parts control Safety A world-class system (WMS) refers to the best practices in that are followed and adopted by various organizations to transform themselves to be a 'world-class manufacturer. R.C.M. Spare parts optimization Root cause analysis Enterprise Asset Planning & Scheduling Maintenance KPIs Kaizen Autonomous 5 S O.E.E. Fault analysis Resources for PM secured

6 Four principles of world-class THE BEST IN CLASS IN MAINTENANCE Empower employees The system s success depends on improving skills and involving employees in the development of new work standards. It includes training in standard as well as in lean methodologies to increase a sense of equipment ownership. Minimize costs Focus on a clear increase in efficiency, reflected in annual cost reductions and reduced spare-parts inventories. Increase asset availability Meeting growing customer demand requires continuous improvement in asset utilization and equipment effectiveness. Shifting from a reactive to a proactive approach can reduce breakdowns and extend the lifespan of equipment. Emphasize Safety & Quality In addition to efficiency, priorities should include safety, environmental impact and product quality.

7 World-class Maintenance benchmark BEST MAINTENANCE PRACTICES Maintenance schedule compliance Maintenance direct work Planned work >90% >75% >90% Maintenance overtime PM schedule compliance The percentage of work covered by a work order Work order actual hours / work order hours planned < 5% 100% 100% % Equipment Productivity Overall Equipment Effectiveness Equipment Availability >90% >77% >95%

8 World-class Maintenance benchmark BEST MAINTENANCE PRACTICES Suppliers costs registered on work orders Materials consumption on work orders Employees hours registered on work orders 100% 100% 100% Work orders opened at least on machine level Equipment tree built at least on machine level Spare parts managed by warehouse Safety stock defined on spare parts >90% >95% >95% >75 % Root cause analysis on work orders breakdowns 5S implemented on workshop and warehouse Condition based activity / total activities >90% 100% >35%

9 MTTR (Mean Time To Repair) hours MTBF / MTTR World-class Maintenance benchmark AVAILABILITY INDEX average good poor good average poor 0 10 MTBF (Mean Time To Failures) days 200 0

10 Performance Assessment GAP ANALYSIS AND STRATEGY DESIGN The performance analysis and evaluation are the main activities identifying the main gaps with reference to the Maintenance Best Practices World class Maintenance targets. Through in-depth analysis of: current status of the 's organization, people skills, related services, tools and best practices, KPIs and budgeting, break-down and failures, continuous improvements process, overall efficiency results of the productivity and reliability. Digitalization processes and Kpis Continuous improvement Maintenance organization and people evaluation PERFOMANCE ASSESSMENT Work orders process, planning and scheduling, tools Costs Control Global assessment on processes and productivity production, gap analysis and benchmark on "best in class". Performance analysis Improvement set-up Classification and mapping of priorities, identification of achievable improvements and related KPIs Redesigning processes, defining new organization, designing digitization process and drafting the development master plan Roadmap design Quality and Safety Process mapping and productivity analysis Warehouse and spareparts optimization Supply chain and vendors

11 AT4 Smart Services

12 Advanced Technology for Smart Services WE EXPAND YOUR SKILLS Advanced Technology... 4 Smart Services digital platform for the best in class of concepts with highest performance on reliability, productivity and efficiency. solutions based on deep learning, machine learning and artificial intelligence fully integrated in the Industrial digitalization process to predict and prevent failures. INDUSTRY 4.0 compliance productive solutions developed with user-friendly web and mobile applications integrated on industry processes. with high performances for the entire Asset Management value chain and the production process. RELIABILITY EFFICIENCY PRODUCTIVITY

13 Drive your power with an integrated smart platform AT4ASSESSMENT Performance assessment. Complete GAP analysis according to WCM and Lean Manufacturing AT4ENGINEERING Maintenance engineering design system. Design and plan all preventive and predictive activities AT4SUPPLIES Supplier qualification, evaluation and invoices system connected to ERP/EAM systems AT4TICKETING Ticketing system as digital call center support AT4SAFETY Safety. All safety parameters are under control AT4PRODUCTIVITY Productivity measurement system (OEE, DT, production lost.) connected to machines, lines and processes AT4MANAGEMENT Enterprise Asset Management system connected to ERP systems AT4RELIABILITY Predictive supervisor systems connected to main equipment for all physics parameters

14 Driving your targets KEEP CONTROL IN YOUR HAND AT4driver is the heart and mind of the platform. Through an interactive smart dashboard you can manage and monitor in real time the complete process and the productivity targets. Linked to the systems and industrial processes systems, AT4driver allows you: to have the complete real-time results, on-time forecast and history on Costs, Productivity, Reliability, Warehouse, Works, Efficiency, Continuous improvement, Quality and Safety to setup KPIs and targets to manage set-points and score of alarms to manage actions on condition and generate automatically proposals in relationship to performance gaps thanks to the concepts based on deep learning, machine learning and artificial intelligence. Everything under control, like driving your car.

15 World-class Maintenance FRAMEWORK MAP Statistical analyses PM optimization L.C.C. World-class Maintenance Condition based Costs Spare parts control Safety A world-class system (WMS) refers to the best practices in that are followed and adopted by various organizations to transform themselves to be a 'world-class manufacturer. R.C.M. Spare parts optimization Rout cause analysis Enterprise Asset Planning & Scheduling Maintenance KPIs Kaizen Autonomous 5 S O.E.E. Fault analysis Resources for PM secured

16 Network concept ALL DATA INTEGRATED IN ONE SAFE WAY Through an Interorganizational Middleware System (Microsoft BizTalk Server) all data are managed with highest standard of security and reliability. One common DB for all data and needs. SMART GRID SMART FACTORY INTERNET OF SERVICES ERP SYSTEMS

17 Main benefits THE REAL ADDED VALUE Cost savings Safety and quality Warehouse Continuous improvem. Better budget s Better expenses Optimization of productivity Optimization of "make or buy" decision process Reduction of energy consumptions Lost time reduction Online global safety results: global index, incident, safety preventive actions Quality and legal traceability: legal requirements, product requirements, on time delivery Reduction of safety risk and incidents Online inventory value Online Inventory Rotation Index (total warehouse and spares) Stock-out Multi warehouse Crtical spare Failures reductions / productive growth Effective policies definition Continuous cost reduction for lack of quality (zero-defects strategy) Continuous cost reduction for non compliance Alarm and tracking on expenditures related to cost center, production line, equipment and types of. Alarm and tracking on legal and quality requirements. Productivity under control, complete traceability of historical events Alarm and tracking on safety stock, inventory value and material expenditures. Warehouse strategy and efficiency completely under control Alarm and tracking on performances and targets. Deep learning, machine learning developed to predict and prevent failures.

18 Services roadmap DRAWING THE ROADMAP AT4S 2 is a scalable and configurable digital platform to facilitate the best practices of (WCM certification) and the of different Service models: 1. SAS - Industrial Specialist Advisory Services 2. TMS - Executive Temporary Management Services 3. PBS - Long term Performance Based Services

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