Challenge

A leading Australian baked goods business was facing poor OEE performance due to high levels of unplanned downtime.

Key challenges included:

  • High  breakdown rate, causing large waste events
  • Under-developed  maintenance strategy and execution
  • Planned  maintenance routines not prioritised and work orders not matching labour  plans
  • Failure  root cause elimination process not effective

The business engaged us to complete a diagnostic of the maintenance processes and capability and develop a prioritised roadmap for implementation to address unplanned downtime  performance.

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Approach

We leveraged our maintenance diagnostic approach to assess each area of asset care capability, together with an in-depth review of breakdown history, including time-to-repair evaluation. Based on the capability profile and the loss-areas, we developed a sequenced plan for implementation, addressing the largest loss-drivers first.

The diagnostic and implementation plan included the following:

1. Maintenance maturity diagnostic

The diagnostic covered the overall fit of the business strategy with the asset care strategy as well as execution. Key elements reviewed included:

  • Equipment ranking and asset criticality
  • Planned maintenance stanards
  • Maintenance planning and scheduling
  • Breakdown elimination and root cause analysis
  • Spare parts and supply control
  • Use of CMMA and KPI monitoring rhythms

Gaps were apparent across multiple areas, with key issues in planning & scheduling as well as breakdown elimination capability

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2. Implementation plan

  • We developed a roadmap for closing gaps across each element with a 4-month hyper care focus on planning &scheduling, as well as breakdown elimination.
  • This included a review of planned / preventative maintenance standards across the highest ranked equipment, with a history of large unplanned downtime contribution
  • We established a performance and progress review cycle with operational leadership stakeholders, supporting capability development
  • The combination of strengthening maintenance disciplines, focusing on the largest loss drivers and prioritising implementation of capability requirements in those areas resulted in a very fast improvement of reduction of chronic breakdown losses.

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Team members involved: Evert Westerhof

This engagement was delivered prior to the team member joining Cinc. The experience and results described reflect work personally delivered by the team member(s) identified above.

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