As part of this effort, GenesisSolutions implemented an advanced RCM program for the injectable vaccine production unit of the Carolina, Puerto Rico plant. Increased month dosage production rates from 3.2M to over 5.0M in 9-months time. In addition, the plant achieved this productivity increase while moving production from three lines to two and achieved associated maintenance and spare parts savings. This is a capacity constrained production unit for a life saving vaccine for infants with a worldwide annual demand of over 60 million dosages.

During the same implementation phase, GenesisSolutions also implemented the same RCM program for the packaging department of the Guayama, Puerto Rico plant resulting in a $240M product throughput increase in the first 4-months of operation. A key part of both programs was the Genesis Reliability Analysis for critical equipment. This approach was based on a Failure Modes and Effects Analysis leading to improved reliability from more proactive and less reactive maintenance, a planning and scheduling partnership between maintenance and operations, better spare parts support and a stronger calibration program.

At both the Carolina and Guayama plants Genesis developed a maintenance planning and scheduling program that includes workflow processes to accomplish annual planning and shutdown planning. An SOP was written, a Planning and Scheduling department created, training conducted for all plant key stakeholders (operations, maintenance and support personnel), in-depth training conducted for plant planner/schedulers and metrics created to track reliability and functional performance. The program was launched using a pilot approach and then deployed plant-wide.

Building a foundation for success requires deliberate, concrete action to propel an organization in a desired direction. Organizations become firmly established and successful in their day-to-day business through careful planning and constant analysis of the work they do. Organizations are, in essence, laying the foundation for success when they use their mission and vision as the target goal; set clear and achievable objectives; have the right people in place to carry out the plans and the technology to support the work. This article demonstrates how a new company with a bold mission is keeping all of those variables in mind as it embraces maintenance excellence as a competitive advantage and a pathway to success.

Talecris Biotherapeutics is a global biotechnology company that discovers, develops and produces critical care treatment for people with life-threatening disorders in a variety of therapeutic areas including immunology, pulmonology, and hemostasis. Talecris is headquartered in the biotech hub Research Triangle Park, N.C., and employs more than 3,000 people worldwide. All of Talecris’ current marketed products are manufactured from human blood plasma – by definition a scarce resource. This precious starting material makes success in the manufacturing process critical.

Talecris Biotherapeutics

Here, we outline the process for building a firm foundation to provide long-term growth and flexibility in the area of Enterprise Asset Management. Talecris Biotherapeutics, Inc. has partnered with GenesisSolutions, one of North America’s leading providers of EAM services, to begin the organization’s transformation.

Read more.

A major North American medical distributor and medical recordkeeping firm needed to upgrade their CMMS system.  The primary driver was to enhance their CMMS system to be more stable and support additional sites.  Genesis was asked to perform the upgrade because of their long successful history with the customer during past upgrades and Genesis’ experience with compliant system.

Genesis Role

Genesis provided the customer with infrastructure and installation expertise, data mapping and migration expertise and integration development skills.  Genesis provided project design and management assistance to this large complex CMMS upgrade project.  Genesis provided data loading services for the new site being implemented during this project.  Genesis also provides long term support for this customer.

Actions Taken

• Upgraded  legacy enterprise CMMS to current release.
• Loaded “green field” data for new site.
• Upgraded and enhanced a work request interface.
• Upgraded reports.
• Provided training for power users.
• Provided business process assistance for one of the large sites.
• Archived historical records.
• Worked with customer architectural tests to design and tune the server systems.
• “Go-Live” support during rollout of new CMMS.

Results Achieved

• Archived 8 million historical work order records to recapture space and increase performance.
• Migrated data from old CMMS to the new CMMS.
• Assisted customer with user and performance testing.
• “Go-Live” support during rollout of new CMMS.
• Users successfully functioning on new CMMS system.
• Continue to provide long term support.

The Customer’s Nutritionals Plant wanted to implement a global Maintenance Excellence Program at all plant sites located in the Americas, Asia and Europe. In addition, the plant in the Philippines needed to significantly improve reliability in order to meet product commitments in the fast growing Asia region.

Genesis Role

Genesis was selected for this strategic project because of deep experience in reliability improvement in major industries worldwide. Our team is helping to define a maintenance excellence vision for each site and a detailed three-year implementation plan to achieve leading-edge reliability. Genesis also deployed a team of reliability and calibration professionals at the Philippines site to help improve reliability and product output in the short-term.

Actions Taken

The project consisted of the following major initiatives:

• Worked with Global Business Unit leadership to define to a Maintenance Excellence vision and implementation strategy
• Conducted a global workshop to introduce reliability and maintenance excellence
• Developed a maintenance excellence implementation plan for each plant in the operating unit.
• Implemented phase I of the program at the Philippines plant including a criticality analysis, calibration program enhancements, reliability engineering improvements on equipment and a PM optimization to improve craft efficiency.
• Developed the reliability program for a plant expansion.

Results Achieved

• Improved reliability and increased output at the Philippines plant. Eliminated the packaging line bottleneck. Eliminated all shipment backlog.
• Implemented cross-functional area improvement teams that are currently generating continuous improvement ideas and increasing product output.
• Completed a knowledge transfer to plant personnel to enable the site to sustain the maintenance excellence and reliability program.

Two organizations at a large government research facility needed to implement changes to their maintenance management processes.The first organization does not use a CMMS, relying heavily on manual procedures to manage its work planning and maintenance operations. It initiated an effort to develop a Work Planning system based on using the facility’s existing CMMS.

Genesis Role

Genesis provided this customer with a list of recommendations on how to use the facility’s existing CMMS to manage its work planning requirements. Genesis provided a Principal Consultant and additional technical personnel to migrate the customer from its manual operation to the CMMS based operation.

Actions Taken

The customer requested assistance in the following areas:

• Enhance the CMMS based on specific operational requirements
• Implement safety and efficiency improvementsImplement critical reports
• Populate the new system with base data
• Provide hands-on training

The second organization uses a CMMS; but, based on audit findings, needed to improve its operating procedures.

Genesis Role

Genesis provided the customer with a detailed plan addressing the development and implementation of a work management methodology based on consistent prioritization, planning and scheduling processes. Genesis provided a Principal consultant and additional technical personnel who worked with the customers’ operating and technical staff to implement the process improvements and to develop the required CMMS enhancements.

Actions Taken

The customer requested specific improvements in the following areas:

• Work planning and schedulingAutomate the preventive maintenance work process.
• Build a workflow process to track work orders from initiation through closure.
• Develop a process to capture non-work time
• Develop reports and KPI’s
• Provide training

Results Achieved

• Both projects launched successful on-time go-live events

The University Facilities Operations and Maintenance department commissioned GenesisSolutions to conduct a review of the use of the current maintenance system and to develop a plan to deploy Maximo at the University.  One of the major drivers for this upgrade was to implement the best-practices- based system solution and establish the foundation for future work process automation alongside a best-practices maintenance process.   The architecture for Maximo 6.2 represents a significant change from the architecture currently in use at the University, as Maximo 6.2 is built on a standards-based Internet architecture and now operates within a web browser.  In addition, Maximo 6.2 offered a new reporting tool, Actuate, and provides a new integration tool, the Maximo Enterprise Adapter (MEA).

GenesisSolutions will provide application and technical assistance to the University  to implement IBM’s Maximo 6 EAM Application.  Genesis was brought in because of their extensive knowledge and ability to provide a complete solution from Gap Analysis to fully implemented production system and support.  In addition, Genesis has an excellent track record working with Facilities of similar size in the higher education industry.

Genesis Role

GenesisSolutions provided various services for the past 4 years.  Genesis was contracted to conduct a detailed Gap Analysis of their current home grown legacy system versus upgrading to Maximo 6.2.  The Gap Analysis was to highlight the technical differences between the two systems, provide method(s) for addressing the differences when upgrading to Maximo 6.2, and recommend the best method based on industry knowledge and UDE’s requirements.  Based on the Gap Analysis, GenesisSolutions was selected as a vendor to conduct the Business Process Review (BPR) sessions, upgrade planning and implementation of Maximo 6.2

Actions Taken

• GenesisSolutions performed the following tasks to upgrade APS EAM System from Maximo 4.1.1 to Maximo 6.2.
• Initial Gap Analysis
• Business Process Review
• Upgrade Implementation Planning
• Project Management support throughout the System Implementation Cycle
• Full implementation support involving the following
  • Architecture and Installation
  • Defining Functional Requirements
  • Configuration and development of Custom solutions
  • Developing interfaces to third party solution via Enterprise Application Interface bus (TIBCO)
  • Unit, System and User Acceptance Testing
  • User Training
  • Go-Live and Post Go Live Support
  • Post Go-Live Enhancements to the system

Results Achieved

• Successful implementation of Maximo 6.2 at the University’s Facilities Operations and Maintenance department.

A major parks and resort needed to upgrade their aging CMMS package to the latest release. The primary reason for upgrading to the new release was to comply with IT policy requiring systems to be within one version of the current release.  A secondary reason was to combine their four legacy CMMS instances into one enterprise instance.  Genesis was brought in because of their extensive knowledge of large, multi-site CMMS installations and experience with merging individual systems into single enterprise systems.

Genesis Role

Genesis provided five technical resources to assist the customers’ project team through the process of merging data, updating integration customizations, upgrading the many integration points and providing guidance and documentation during the testing phases.  Genesis guided and supported the very experienced CMMS business test through the process of translating business process from the old CMMS to the new CMMS.

Actions Taken

The customer requested assistance and guidance in the following areas:

• Project management and planning for this multi-phase implementation.
• Installation design and testing for the large, complex system architecture.
• Upgrade customizations to current technology.
• Complex data mapping and merging of data.
• Liaison between customer and CMMS vendor for product issues.
• Assist customer training department with training plan
• “Go-Live” support during and after the multiple rollouts of new CMMS.

Results Achieved

• Four legacy databases were merged and upgraded into one.
• Integrations between the CMMS and external systems were updated.
• A new maintenance planning and scheduling add-on was deployed.
• Custom help screens were deployed.
• Reports were upgraded.
• Performance tests conducted.
• Functional tests conducted.
• Documentation provided.
• New release was deployed in phases for the large domestic and international user community.

The customer was awarded the Institutional Services Contract (ISC) for the John F. Kennedy Space Center. The ISC manages facilities, shuttle propellants, life support equipment, laboratory, calibration and non-shuttle logistics for NASA at the nation’s manned flight launch site. The customer’s requirements included using Maximo 6.2 as part of the contract statement of work. Although NASA provided the server hardware and software, and the incumbent contractor was responsible for data migration from version 4, the customer was required to develop new processes, procedures and any necessary customizations for their business processes by contract start, a period of 90 days.

Genesis Role

Two Principal Consultants from GenesisSolutions provided support to the customer in all aspects of the implementation of Maximo 6.2. Due to delays, GenesisSolutions had only a 45 day period to begin the design of an entirely business process.

Actions Taken

In the six weeks preceding go-live, GenesisSolutions provided or assisted in the Maximo 6.2 implementation by:

• establishing all initial business processes for every sector of the contract using Maximo
• extensive data validation of migrated data
• modification of screens and applications
• coordination and integration points to the corporate Costpoint financial system
• training for over 400 Maximo hands-on users

Subsequent to go-live, GenesisSolutions provided on-going support in the form of continuing enhancements to Maximo as well as process improvements to the customer.

These included:

• developing Workflows for desktop requisition, utility outage and work order processes
• developing Actuate reports, queries and KPIs
• custom application development
• facilitating training of in-house personnel
• design documentation
• documentation of procedures

Results Achieved

• New release was rapidly and successfully implemented
• No launch delays were incurred as a consequence of the contract changeover and/or Maximo implementation
• Maximo implementation was cited as a strong point at the first 6-month Contract Management Review

A major chemical manufacturer needed to implement a new CMMS to replace their aging system and integrate to their financial package. The primary reasons for implementing a new CMMS involved standardizing systems and maintenance practices across the company.
Genesis was brought in because of the following:

• extensive experience with the new CMMS
• proven track record for implementing and standardizing maintenance best-practices in a multi-site, multi-national environment
• demonstrated ability to implement the new CMMS with the customer’s existing financial system
• successful history of bringing in similar large-scale complex efforts on time and on budget

Genesis Role

Genesis led and staffed numerous key roles for this effort to include:

• Project Management
• Business process and best-practice development
• Technical and Integration resources
• Report and KPI development
• Training development and delivery
• Go-live and post go-live support

Actions Taken

Over the course of this project, Genesis followed a tried and true implementation methodology to ensure project success.  This process involves:

• Assessment / GAP
• User Requirements
• Functional Requirements
• Design
• Development
• Testing
• Training
• Cut-Over / Go-Live
• Support

Results Achieved

At the end of this effort, the new CMMS was successfully implemented and was integrated to the financial system.  All project objectives were met to include timeline and budget.

A major cement manufacturer needed to upgrade their aging CMMS package to the latest release. The primary reason for upgrading to the new release was to consolidate 26 individual systems to one central system. The central system also included 2 countries and 2 languages.

Genesis was brought in because of their extensive knowledge of unique manufacturing CMMS needs and because of their excellent track record working with companies of similar design.

Genesis Role

Because the customer had a seasoned and experienced development team, Genesis provided a seasoned Project Manager to manage the project. The Project Manager also acted as Principal consultant to assist them on the more advanced features of the new CMMS package.

Genesis also provided Engineering expertise to search numerous facilities for equipment, location and inventory data necessary for the new system.

Actions Taken

The customer requested specific knowledge transfer in the following areas:

Integration expertise including design and implementation

Understanding of multiple site, organization and language systems.

Detailed data mapping between the old and the new CMMS.

Full explanation and mapping of new CMMS applications.

Advanced techniques for ensuring data integrity after conversions.

Hands-on training covering all new functionality.

Develop procedures for inventory data cleansing and importing to financial system

“Go-Live” support during rollout of new CMMS.

Results Achieved

New release was rapidly and successfully implemented, bringing all 26 sites onto a single centralized system. The system was able to facilitate 2 languages on one system.

Users were effectively trained in new systems functionality.