Manufacturing

Asset Management in Manufacturing Industry

The purpose of Asset Management in a manufacturing environment is two-fold.

  • Firstly ensuring all of the physical assets relating to the production process; including the production line equipment and the associated facilities, are operating in a safe controlled environment in accordance with the required industry, national and international standards.
  • Secondly ensuring that the production line can maximise its productivity by eliminating unplanned maintenance, and scheduling the required maintenance as efficiently as possible.

Many manufacturing companies who make complex assets, also offer maintenance services to the customers they have sold the manufactured items to. In this case asset management is about ensuring that the assets under maintenance perform according to the agreement in place with the customer.

Manufacturing Industry Challenges 

The term ‘Manufacturing Industry’ covers a wide range of very diverse processes in numerous sub-sections (e.g. pulp and paper, vehicle manufacturing, food processing, chemicals, pharmaceuticals, mining and steel etc.). Each of these sub-sections will have some challenges that are unique, but there are equally a number of common themes that run across the industry as a whole. These include:

  • Maximising productive output and maintaining product quality whilst minimising breakdowns (i.e. maximising OEE – overall equipment effectiveness)
  • Minimising the stock of spare parts kept for maintenance purposes
  • Managing appropriate maintenance strategies for when the plant is operating at full capacity and for when the plant can afford to have equipment out of production.
  • Maintaining a safe work environment
  • Making effective use of ‘planned outages’
  • Maximising Labour productivity
  • Recording the direct and indirect costs associated with maintenance activity

MACS Manufacturing Customers

MACS Customers in manufacturing range from manufacturing carpets to cardboard boxes, from pharmaceuticals to ceramic tiles and from aluminium extrusion to confectionary. Each has a Maximo system configured to suit their own individual needs, but delivering value through best practice asset management processes.

MACS have years of experience in providing asset management and scheduling solutions to manufacturing companies. Maximo is recognised by Gartner as the leading Enterprise Asset Management Solution. MACS have been implementing Maximo for over 17 years. Maximo provides functionality to support

  • Asset Register
  • Preventive Maintenance
  • Work Order Management
  • Inventory Control
  • Procurement
  • Service and Contract Management
Scheduling maintenance work in conjunction with production planned and unplanned outages is a big challenge and Maximo Scheduler is capable of supporting the optimisation of many of the common scheduling scenarios that occur in the industry. These include daily work allocation to technicians as well as project based scenarios related to outage management.
Maximo Mobile solutions serve to improve the productivity and accuracy of data within both the production line and field based service scenarios. Working in both connected and disconnected mode these solutions enable maintenance technicians to readily see what activity needs doing, to access on-line drawings and manuals, to update and complete work, and to raise new work orders where required.
For service operations maintaining assets on behalf of customers, Maximo for Service Providers enables customer specific price agreements to be input which support activity based pricing as well as activity based costing, thus supporting contract profitability calculations and the preparation of customer invoices.