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.

The customer needed to improve their maintenance work processes, implement a reliability engineering program, upgrade the CMMS to support the changes and implement a governance organization to support the change effort and to sustain the gains after the project was completed. Genesis was selected to assist because of our experience in maintenance and reliability best-practices, CMMS systems and in organizational change management across all industrial sectors and in government environments.

Genesis Role

The project began with a GAP analysis between leading-edge practices and the current state. A number of major initiatives were identified and Genesis teams deployed to implement improvements to close the gaps, establish metrics to track improvements and train the customer’s personnel to transfer knowledge.

Actions Taken

The project consisted of the following major initiatives:

• Establish a Maintenance best-practices steering committee
• Define an Asset Lifecycle Management Program
• Criticality analysis
• Maintenance workflow reengineering and redesign
• Planning and scheduling enhancements
• Implement a Reliability Engineering program
• Complete a PM optimization in one area critical to operations
• Normalize multi-storeroom inventory data to support coordinated usage and strategic sourcing
• Establish key performance indicators reporting and tracking

Results Achieved

• A Maintenance Best-practices Steering Committee consisting of a cross section of management was established and remains in place to guide continuous improvement
• Maintenance workflows were successfully redesigned and planning and scheduling practices changed to improve craft effectiveness
• PM optimization was completed with a reduction in FTE required to complete PM work. These FTE were redeployed to a Greenfield site to avoid adding additional maintenance crafts.
• KPIs (Key Performance Indicators) were established and a reporting mechanism implemented

A major off-shore Oil/Gas operator needed to reduce work order backlog while preparing their CMMS data and functionality for a system upgrade in the future.

Genesis was brought in to fill a need for concentrated planning and scheduling of several rotating “campaign” teams being utilized to work on backlog work and mini-projects that were outside the routine work of the core maintenance team. Genesis was chosen because of their extensive knowledge of the CMMS, planning and scheduling expertise, along with resources with extensive experience in off-shore Oil/Gas maintenance and management.

Genesis Role

Genesis was asked to provide a complete team, Delivery Lead and 3 discipline engineers in Mechanical, Electrical and Instrumentation.

Actions Taken

The customer asked Genesis to:

• Coordinate work packs for offshore teams which would include grouped preventive maintenance work orders for critical systems along with all corrective and modification work for the same systems.
• Daily management of team schedule and reporting of progress against plan and backlog reduction.
• Review and improvement of maintenance routines, scheduling, planned labor/material and maintenance effectiveness for critical systems.
• Assist in the development of corporate maintenance strategy as it relates to off-shore asset reliability.
• Development of new process flows for all activities related to off-shore maintenance activities.
• Cleanup of CMMS data in preparation for upgrade of system

Results Achieved

• To date 40% reduction of backlog hours
• Review/improvement to 20% of the critical system maintenance plans
• Preparation and coordination of work packs for campaign teams through 5 tours to date

A major Oil/Gas producer needed help in identification of their major safety related equipment/systems, loading of that data to their CMMS system and review/update of their maintenance plans to assure the integrity of these important assets.

Genesis was brought in because of their extensive knowledge in asset maintenance, risk analysis, development/improvement of maintenance strategies, CMMS data improvement and because of their excellent track record working with companies with similar needs.

Genesis Role

Because of the unavailability of the company’s Maintenance and Engineering resources, Genesis was asked to provide, Project Management, Safety Engineers, and Discipline Engineers with experience on off-shore assets and process engineers with heavy documentation experience. (7 consultants)

Actions Taken

The customer requested our help in the following areas:

• Review of 220,000 offshore assets
• Identification and categorization of 85,000 safety related assets.
• Load of information to the CMMS and link to their desktop Facility Status reporting tool
• Development of 180 Safety Performance Standards for above equipment
• Analysis of existing maintenance routines to the new performance standards
• Linking of the above information to the quality module in their CMMS

Results Achieved

• All safety related assets identified and maintained in CMMS
• Performance Standards developed and published for use
• Facility Status Reporting functional and globally rolled out
• Beginning work on rollout of CMMS quality module and the link to work orders