Client Profile: U.S. Recycler
Challenge
- The client had multiple production facilities across North America, with a centralized maintenance support team and on-site maintenance technicians.
- Other than major outages, very little work was planned, with most work being reactionary work after equipment failures.
- Client had no CMMS or formalized work management processes. Work requests from operations came to maintenance via email with no tracking mechanisms.
- There was minimal critical spares across the network and limited common spares.
- Maintenance spare parts were stored in the facility workshops without any network visibility to either on-hand inventory or consumption.
Approach
- Designed a Maintenance Management Operating System including weekly backlog reviews, scheduling meetings, and KPI reviews
- Installed an MS Office –based CMMS system utilizing online forms and Excel tables to categorize work requests through completed scheduled work orders
- Worked with major equipment vendors to develop a list of critical spares for each facility, audited spares on-hand throughout the network and managed the sourcing and procurement of the needed spares
- Designed secure spare parts cages, with controlled access to store and inventory spares.
- Worked with Supply Chain team to integrate spare parts into ERP system and create methodology to manage inventory on-site.
Solutions
- CMMS system creation
- Critical Spares review & update
- Dedicated Spare Parts crib, with system inventory
- Work Order Management System
- Management Operating Systems, including KPI’s and weekly meetings cadence
- Data Analytics
Result
- Equipment uptime increased from ≈50% to over 75% over a three-month period
- Developed and Installed 30-40 critical Operator Based Care Activities that drove over 100 work notifications
- Emergency Work Orders were dramatically reduced at each production facility
- Weekly Preventative Maintenance completion rate increased from ≈25% to 100% consistently.
- Over $5 Million in critical spare parts were identified and purchased
”As One came in and helped the team focus on what really matters, which is planned and scheduled maintenance. With the proper work identification, planning, scheduling and execution, we are able to increase plant availability by efficiently performing maintenance.”
- Maintenance Manager
