MCP Consul*ng Group Limited AMIS

Transcription

1 MCP Consul*ng Group Limited AMIS Febuary 2017 Richard Fathers

2 MCP Creden*als Est staff in UK 20 staff in Europe 50 associates worldwide Partners in other disciplines N America: USA Chicago Canada: Toronto UK Solihull, W Midlands, Reading, Derby Europe Spain, Portugal Sweden, Austria, Germany Focus is High Risk, High Impact organisa*ons Support our clients with Consul@ng & Training in: Manufacturing, Maintenance, Asset Management Specialise in Food & Drink, Facili@es, Pharmaceu@cal Automo@ve Chemical, Power Links with CMMS suppliers - Maximo, SAP, Mainsaver Middle East Abu Dhabi, Jordan China MCP Consul@ng & Training Ltd Not to be reproduced without permission Slide No. 2

3 MCP Customers MCP & Training Ltd Not to be reproduced without permission Slide No. 3

4 What is AMIS? AMIS Asset Management Improvement System incorporates a benchmarking tool Developed in UK by MCP; used by 4000 sites worldwide to improve maintenance (Asset Management) Based on Best Practice Standard approach to ensure consistency MCP Consul@ng & Training Ltd Not to be reproduced without permission Slide No. 4

5 AMIS Background Assessment of maintenance practices, systems, methods Based on a best practice model for asset management Use Self-appraisal process Benchmark to external best practice Comparison with >4000 audits worldwide Sector specific comparisons Average 1 st time assessment score 20-30% Target: World Class status > 75% MCP Consul@ng & Training Ltd Not to be reproduced without permission Slide No. 5

6 MCP s 4 Stage Approach for Improvement Stage 1 Benchmarking & Assessment Find the gaps against best prac@ce standard using AMIS Stage 2 Implementa@on planning Design the business processes and systems that will support the desired change Stage 3 Implementa@on Train / Support / Coach Stage 4 Review Plan Check and audit MCP Consul@ng & Training Ltd Not to be reproduced without permission Slide No. 6

7 AMIS Categories & Focus Areas 1 Assess how well the asset care strategy is driving the key areas of: General Maintenance 2. Organisa@on 3. Work Planning 4. Cost Management 5. Produc@vity & Effec@veness 6. Materials Management 7. Failure Analysis & C.I. 8. Training & Safety MCP Consul@ng & Training Ltd Not to be reproduced without permission Slide No. 7

8 Audit Programme 1 - (3 days on- site) Assessment by representa@ve team of company s engineers and produc@on people Review Organisa@on & Maintenance data (Part I Ques@onnaire ) Self assessment to AMIS standard (Part 2 Ques@onnaire ) Plant tour Teams use Ques@onnaires for Produc@on and Maintenance staff survey Collect data on maintenance and manufacturing performance Develop ideas and ac@ons Calculate scores Iden@fy opportuni@es for improvement Brainstorming to develop ac@on plans Feedback to site management Summary Report MCP Consul@ng & Training Ltd Not to be reproduced without permission Slide No. 8

9 Team Composi*on Typical Engineering Manager Engineering Team Leader/ Supervisors Process Engineers Operators Technicians Maintenance Planner Storekeeper Training Manager Manager/ Supervisor Improvement Champion Team members spend all the day 1 plus on each remaining day Core group selected to spend all with MCP assessor Assessment is site led supported by MCP MCP Consul@ng & Training Ltd Not to be reproduced without permission Slide No. 9

10 AMIS Aquatera Results All MAINTENANCE MANAGEMENT Max Sectors Water Sector Scores CATEGORY Points Ave Low Average High Aquatera % % % % 1. General Maintenance Level Organisation and Administration Workload Planning and Control Cost Management Productivity and Maintenance Effectiveness Materials Management Failure Analysis and Betterment Training and Safety PLANNING INDEX EFFECTIVENESS INDEX COST INDEX ORGANISATION INDEX OVERALL EFFECTIVENESS INDEX MCP Consul@ng & Training Ltd Not to be reproduced without permission Slide No. 10

11 Results by Management Category MCP & Training Ltd Not to be reproduced without permission Slide No. 11

12 Industry Comparison MCP & Training Ltd Not to be reproduced without permission Slide No. 12

13 Aquatera Pyramid World Class Performance Reliable Equipment & Processes Performing, motivated teams Reliability Engineering Life Cycle Costing Continuous Improvement Aligned responsibilities Succession Succession Planning High Labour Utilisation New Equipment Management Work Scheduling Asset History Operator Asset Care Maintenanc Metrics & Reports Maintenanc Cost Prediction Work Planning Maintenance Cost Recording Critical Equipment & spares Spares Provisioning Admin and Support Standard Jobs Cost Accountability Assets In Maintainable Condition Strategy Aligned Organisation Safe Working Work Recording Planned Preventive Maintenance Correct Maintenance Skills Work Place Organisation Team Working MCP & Training Ltd Not to be reproduced without permission Slide No. 13

14 Aquatera Journey to World Class MCP & Training Ltd Not to be reproduced without permission Slide No. 14

15 AMIS % 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 37% 53% AMIS Projec*on Actual Projec@on World Class High benefits as all people engaged 65% Asset Care Excellence 74% 81% Maintenance Excellence Limited benefits as ~60 people engaged 86% Exceptional Plant Performance World Class Processes 0% MCP Consul@ng & Training Ltd Not to be reproduced without permission Slide No. 15

16 THE ORGANISATION WANTS Highest Possible Equipment, Building and People Reliability Opera*ng Excellence Depends on.3 things Operation 40-50% OBW to Operate Adherence to OBW Operator Asset Care Preventing failures OEE CI activities Skills and Training Design 30-40% Fit for purpose DO opportunities Built in reliability Ease of Operation Ease of Maintenance CI modifications Maintenance 10-30% Risk Management FMECA / RCM Maintenance Plans Delivery of Plans Maintainability CI activities DOERS NEED THE BEST SUPPORT SYSTEMS, DATA AND PROCEDURES MCP Consul@ng & Training Ltd Not to be reproduced without permission Slide No. 16

17 2017 MCP & Training Ltd Not to be reproduced without permission Slide No. 17

18 2017 All MAINTENANCE MANAGEMENT Max Sectors Water Sector Scores CATEGORY Points Ave Low Average High Aquatera % % % % 1. General Maintenance Level Organisation and Administration Workload Planning and Control Cost Management Productivity and Maintenance Effectiveness Materials Management Failure Analysis and Betterment Training and Safety PLANNING INDEX EFFECTIVENESS INDEX COST INDEX ORGANISATION INDEX OVERALL EFFECTIVENESS INDEX MCP Consul@ng & Training Ltd Not to be reproduced without permission Slide No. 18

19 Typically Implemen*ng An Asset Care Strategy Would Provide The Following Range Of Benefits : Lower cost of repairs fewer spares and less time Fewer surprise breakdowns and risks to supplying customers Less catch-up time on overtime Better equipment reliability from Risk Based Maintenance Release of equipment capacity able to delay future investment needs Maintenance involvement in equipment selection lower life cycle costs More sensitive operation of equipment Better man-power utilisation avoiding delays Fewer rejects, less waste, more yield from materials Operators doing 1 st level maintenance ownership of equipment Technicians released to do diagnostic work longer term All employees following the same strategy guideline MCP Consul@ng & Training Ltd Not to be reproduced without permission Slide No. 19

20 Benefits Con*nued: Improved equipment set-up leading to. lower energy usage improved quality more reliable performance Improved morale Asset Care seen as a positive contribution to business performance Ownership of workplace processes and KPI s leading to a CI culture and business savings Training that provides the tools and techniques is considered a vital pillar No training No knowledge No improvement No business!! Typically form an average position, cost savings of 20% of current expenditure is considered to be obtainable over say the next 2-3 years. Successful CI activity could (and should) exceed this figure. MCP Consul@ng & Training Ltd Not to be reproduced without permission Slide No. 20

21 Examples : But What Could You Achieve? Produc@vity Increased by 20% Manufacturing Costs Reduced by 20% Quality Costs Reduced by 30% Maintenance Costs Reduced by 20% Performance/Efficiency Greater than 85% Number of Breakdowns Reduced by 50% Number of CI Sugges@ons Increased by 500% Workforce Involvement Greater than 80% Number of Accidents Reduced by 50% MCP Consul@ng & Training Ltd Not to be reproduced without permission Slide No. 21

22 Thank you Thank you Any Ques*ons? MCP: +44 (0) visit: MCP Ltd Not to be reproduced without permission Slide No. 22