SIMAIN -We care. Business Based Maintenance. August Siemens AG All Rights Reserved.

Transcription

1 SIMAIN -We care. Business Based August 2009 Siemens AG All Rights Reserved.

2 SIMAIN Business Based Your Challenge Our Approach Awareness Analysis Feasibility Implementation & Sustainability Your Benefits References Contact Page 2

3 Maintaining your production plant means you are facing many challenges in your daily business Can I reduce my spare parts stocks to free money for other needs? How can I increase my production without investing in new equipment? Can my maintenance costs be flexible enough to cope with market fluctuations? How can I ensure the availability and reliability of my production plant in a sustainable way? Can I entrust my maintenance operations to an external partner? Page 3

4 Customer benefits examples Improvement Bild 1 Increased plant availability +5% Continuous maintenance cost reduction Increased plant efficiency +8,3% Smurfit Kappa Baden Karton GmbH Deutschland MTU Aero Engines Deutschland PaperLinX Australien Page 4

5 Your main challenge is flexibility in aligning your business targets and maintenance strategy Cost Total Cost Variation due to market changes Optimized Costs Costs Production Losses Adapting maintenance strategy to business requirements Intensity Page 5

6 Our core competence is to improve and manage maintenance processes Based on the many years of Siemens experience and our extensive maintenance management expertise, we care to identify strengths & weaknesses within your organization, measure your process maturity, benchmark your organization within your industry, identify your improvement potential, define measures and targets, implement measures and check the results, assure continuous improvement within all areas of maintenance. Page 6

7 The SIMAIN Model (Siemens perspective) Inputs: Business Strategy External Requirements - Legal Demands Enablers: Spare Parts Management Personnel CMMS System Documentation Management Organization Contractor Management Engineering Plan Plan Planning Plan Plan Act HS&E Do Act Cost Do Scheduling Do Availability / Reliability Act Do Capital Investment Act Check Check Execution Check Check Performance Control (KPI) HS&E: Health, Safety & Environment Page 7

8 The SIMAIN Model (Customer s perspective) Value Profit Capital Employed Cost Sales Plan Plan Plan Plan Act HS&E Do Act Cost Do Do Availability / Reliability Act Do Capital Investment Act Check Check Check Check HS&E: Health, Safety & Environment Page 8

9 We support you in making maintenance excellence come true Awareness Analysis Feasibility Implementation & Sustainability Health Check Business Review Alignment Workshop Maintenanc e Improveme nt Program Business Simulation Integral Plant Maintenanc e Added Value Value Go/No-Go Decision Page 9

10 The Health Check gives a professional overview of your maintenance organization Why Health Check? We help you identify your strengths and weaknesses Evaluation of all aspects of your maintenance organization in 7 categories We point out your main maintenance improvement opportunities We give a professional overview of your maintenance management processes We give you an estimation of your savings potential Our approach Planning & Scheduling Equipment Strategies Asset Management Performance Control Personnel & Resources We provide the basis for a confident decision on the next steps Processes Spares & Resources Page 10

11 Within 2 days, we give you a first glance on your maintenance operation s maturity Pre-questionnaire Two days on site Presentation & report Fill out questionnaire Review pre-questionnaire Plant Tour SWOT-Workshop with key roles Interviews Final evaluation Presentation of results to your management Our deliverables Estimated Improvement Potential Estimated financial improvement potential SWOT analysis List of top improvement measures Maturity assessment: current and potential Suggestions for next steps Availability Contractors Spare Parts Personnel Page 11

12 Our Business Review provides a detailed analysis of your maintenance processes Why Business Review? You get a detailed analysis of your maintenance organization We give clear statements on the financial improvement potential We benchmark your maintenance processes with best in class We give recommendations for improvement in each of the assessed processes Our Approach 7.2 Major Overhauls 7.1 Planning & Scheduling Asset Life Cycle Cost Mgmt aintenance Strategy & Plan Development 6.1 Operational Analysis 6.5 Asset Mgmt Plan Equipment Condition Monitoring 5.4 Fault Mgmt ance Mgmt Information System 5.2 Equipment Performance Analysis 5.1 Standard Procedures & Job Instructions 4.4 Workshops 4.3 Subcontractor Mgmt 1.1 Mgmt Commitment & Leadership Policy 1.3 Improvement Program 1.4 Risk Mgmt 1.5 Quality Assurance 2.1 Financial Control 2.2 Equipment Performance Co 2.3 Mgmt Review Program 2.4 Health & Safety Mgmt & Trai 3.1 Organization Structure 3.2 Workforce Involvement & Participatio 3.3 Personnel Development Program 4.1 Spare Parts & Procurement Material Planning 4.2 Warehouse Mgmt We develop a detailed concept and project plan for implementing improvement measures Asset Management Performance Control Personnel & Organization Spares & Resources Processes Equipment Maint. Strategies Planning & Scheduling Page 12

13 Our Business Simulation visualizes improvement scenarios Modeling the organization Simulating scenarios Assessment and data collection Model creation Simulation Improvements / Modifications Results Results analysis Report generation Deliverables Simulation of "what if"-improvement scenarios by testing before doing Illustration of decision making arguments by visualization of different measures, investments and impacts that affect the maintenance organization Summarizing of the total improvement potential of different scenarios Development of a project plan and an estimated return on investment (ROI) calculation Page 13

14 We assess the processes on site and deliver the findings and recommendations in a detailed report 1 to 2 weeks Preliminary information On-site analysis Presentation & report Pre-questionnaire (complementary to Health Check) Interviews & in-depth analysis (with employees on all hierarchy levels and in all relevant departments) Presentation & report (including improvement potential, benchmarking and recommended actions) QUESTIONNAIRE QUESTIONNAIRE QUESTIONNAIRE Page 14

15 Our analysis phase delivers quantified improvement potentials Our deliverables Visualization of measures, investments and impacts to give decision making arguments Evaluated catalog of measures Estimated return on investment (ROI) calculation Savings Potential Quantification of the improvement potential 9,0% 8,0% 7,0% 6,0% 5,0% 4,0% 3,0% 2,0% 1,0% 0,0% 2.3% Spare Parts Management 5.6% Organization Orgnisationsstruktur Structure 4.6% Subcontractor Management 0.7% Workshops and Repairs 8.0% Major Shutdowns CATALOG OF MEASURES With our detailed analysis we enable you to decide upon your improvement measures 1. Asset Management 2. Performance Control 3. Personnel & Organization 4. Spares & Resources 5. Processes 6. Equipment Strategies 7. Planning & Scheduling Page 15

16 With our feasibility analysis we enable you to start your step-by-step improvement measures Why Alignment Workshop? We analyze the necessary staffing and organizational requirements You get a study on the technical and economic feasibility of the identified measures From the results we define the priorities in close collaboration with you As a result you receive a roadmap for maintenance improvement measures Implementation roadmap Page 16

17 The Alignment Workshop delivers a specific project plan best suited to customer needs SWOT Workshop Review Reports Improvement Potential Strategic Goals Measure Development Analyzed Risks Countermeasures Prioritized Actions Helpful to achieving the objectives Harmful to achieving the objectives Internal origin (t o the organiz ation) Strengths Weaknesses External origin (from the environment) Opportunities Threats Deliverables In close collaboration with your maintenance organization, we identify the main value drivers develop strategic goals for the maintenance organization assess strengths and weaknesses, analyze threats and define countermeasures calculate the estimated return on investment (ROI) define a customer-tailored improvement concept and a high-level project plan Page 17

18 We support you in achieving your targets Why Improvement Program? To improve your maintenance organization and processes, you need maintenance expertise, a systematic approach, qualified resources, and management attention We can provide you all with requisites to achieve the improvement targets, with best practices know how from projects in all industries and around the world with a systematic approach based on the SIMAIN Handbook with professional support for your change management with qualified project management with training and coaching in a KPI performance-based improvement project Page 18

19 Your customized SIMAIN Handbook We customize our extensive know-how to your business needs by taking into account: Inputs: Business Strategy External Requirements -Legal Demands Enablers: Spare Parts Management Personal CMMS System Documentation Management Organization Contractor Management Engineering Plan Plan Planning Plan Plan Your targets and strategy Act HS&E Do Act Cost Do Scheduling Do Availability Check Do Capital Investment Check Your organization and competences Your process requirements The improvement potential verified in the previous phases Your internal best practices Your existing CMMS and data structure Contents Performance Control Spares and Resources Equipment Strategies Check Asset Management Check Personnel and Organization Processes Planning and Scheduling Execution Act Performance Control (KPI) Standard procedures Training Act Standard tools and reports Page 19

20 The Improvement Program is our systematic approach to the implementation phase Alignment Concept Implementation Coaching business strategy Mission / vision Targets and objectives KPI cockpit Future organization Project timeline Project team Customization of the SIMAIN Handbook Workshops to map and define customer processes Development of the specific handbook chapters Training of project team Definition of tools and reports Change management Taking the concept to the shop floor Focus on low-hanging fruit Training of all teams CMMS integration Intensive use of new tools Learning by doing Constant follow-up and coaching Process maturity achievement KPI controlling Continuous improvement Page 20

21 Integral Plant - Ensuring long-term partnership and sustainable improvement Operations (MOP) You want to achieve long-term and sustainable improvement in you maintenance organization while focusing on your core business You need a competent partner that provides the right level of management attention and expertise Motor Management Program (MMP) Your motors are the heart of your production, they need to be maintained and kept at the most efficient level This requires adequate expertise and resources We offer a long-term partnership for your maintenance and resource management We generate value through performance-based contracts controlled by defined KPIs You have the choice between two maintenance contracting models: We can manage the maintenance and repair of all your motors, thereby boosting reliability, reducing costs and cutting inventory levels Traditional outsourcing Partnership model Page 21

22 We can operate your maintenance processes in either an outsourcing or a joint-venture partnership Operations (MOP) Traditional outsourcing Partnership model If you want to concentrate on your core business, we are your reliable partner for managing your maintenance organization as a responsible contracting partner We manage your maintenance processes on the basis of a performance-based contract If you consider maintenance to be your key competence, we can collaborate on the basis of a partnership model with your company Page 22

23 Business Based means optimization and continuous improvement Performance Integral Plant Improvement Project Continuous improvement of maintenance management (KPI-based decision making) Regular Operations Time Page 23

24 Benefits from sustainable productivity and efficiency improvement based on Siemens experience My cost improvement: >10% of the maintenance budget My OEE has improved by 3% My spare parts stock is reduced by 10% The maintenance targets are aligned with my business targets I can concentrate on my core business Page 24

25 Our project partners Customers who already trust us (GER, FRA) (FIN,GER, SWD) (GER) (COL) (UK, Benelux) (COL) (AUS) (CZE) (GER) (USA) (USA) Page 25

26 Thank your for your attention! Page 26

27 We care that s our promise! Your Sales Contact Your Product Portfolio Manager Alexandre Cottini Mendes Product Portfolio Manager Asset Performance Management I IS IN OLM MS Günther-Scharowsky-Straße 2 D Erlangen Phone: +49 (9131) Fax: +49 (9131) alexandre.mendes@siemens.com Page 27