When: 2/22/10 - 2/25/10

ISPE, the International Society for Pharmaceutical Engineering, is the world’s largest not-for-profit association dedicated to educating and advancing pharmaceutical manufacturing professionals and their industry. Founded in 1980, today ISPE serves 25,000 members in 90 countries.

GenesisSolutions will be exhibiting in booth #76 and presenting on Thursday, February 25th (Mr. Mike Greenholtz - Discussing Wyeth Pharmaceutical’s Maintenance Excellence Program).

When: 2/21/10 – 2/24/10

 Find out how a smarter planet requires a dynamic infrastructure based on IBM service management capabilities.

• More than 200 customers will present first-hand experience to provide invaluable knowledge to all attendees
• IBM executives and industry leaders share how IBM service management can deliver smarter service on any scale
• IBM booth showcasing more than 100 real-world solutions
• More than 100 business partner exhibits in our enhanced solution expo
• Pre- and post-conference education
• Join our sponsors and showcase your solutions at the premier service management event.
• Self-paced, technical, hands-on labs and product certification
• IBM service management health-checks to diagnose your service management environment

GenesisSolutions is a Silver Sponsor of this event. Please visit us in booth # S419. We will also be co-presenting with Wyeth Pharmaceuticals & Port of Seattle.  More information is available at the IBM Pulse 2010 Website: IBM Pulse 2010

Walter Betsill began his career in 1986 as a mechanical engineer in the chemical industry after graduating from Clemson University.  Walter was involved with many aspects of industrial activities including the retrofit of several aged and specialized HVAC systems to support clean rooms and laboratory environments.  He was member of several forward thinking teams investigating the implementation of predictive and condition based technologies to reduce down time and operational costs.  Walter was part of a team working toward improving the partnership between engineering, operations and maintenance.  He achieved certification from the Association of Facilities and Plant Engineers, now AFE.

In 1993, Walter took an opportunity to become a field consultant for Datastream Systems.  In this role, Walter was able to leverage his knowledge of industrial asset management and maintenance to help customers implement Datastream’s CMMS product (MP2) and realize gains from improved maintenance processes recordkeeping.  These customers represented verticals including heavy industry, municipalities, hospitals and universities. In 1996, Walter and several of his peers joined PSDI (the precursor to MRO Software and now IBM), the developers of Maximo.  At PSDI, Walter managed a number of the largest and most complex Maximo implementations.  The majority of these projects involved organizations that had multiple sites connecting to a single CMMS system.  Walter also assisted many customers in developing strategies to both improve their business processes and to deploy the correct technology in support of these initiatives.

In 1999, Walter joined GenesisSolutions as a founding member of the consulting staff and continued to lead many large, complex projects.  He became the manager of Genesis’ Technical Services team and developed a series of internal training programs to continue to enhance the skills of the organization.  Walter continues to promote the philosophy that Genesis is a large team of diverse experts dedicated to providing the right solutions to customers at a competitive price.

Bluewater Energy Services: Maintenance Planning and System Optimization

Bluewater Energy Services, a major off-shore Oil & Gas operator, needed assistance on one of their Floating Production, Storage and Offloading (FPSO) Vessels on the North Sea to reduce work order backlog (+50,000 hours), improve maintenance plans and prepare their Computerized Maintenance Management System (CMMS) data for a system upgrade in the near future.

GenesisSolutions 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. Chosen for our extensive knowledge of their Maximo CMMS, planning and scheduling expertise, along with resources with extensive experience in off-shore Oil & Gas maintenance and management, Genesis was asked to provide a complete team consisting of a Delivery Lead and 3 discipline engineers in Mechanical, Electrical and Instrumentation. 

Actions taken by GenesisSolutions to satisfy customer project requirements:

• Coordinate work packs for offshore teams which would include grouped preventive maintenance work orders for critical systems along with all corrective and modification work
• 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 system upgrade

After a multi-year effort, the following results were achieved:

• 85% reduction of backlog hours to a manageable level (to date)
• Review / improvement to 100% of the critical system maintenance plans
• Preparation and coordination of the campaign teams until the customer was able to take over and absorb the teams into their core crew after a successful 9 month period under GenesisSolutions direct coordination
• Maximo system data updated and aligned for the future system upgrade

Tony Vaclavicek, Manager of Reliability Services, GenesisSolutions European Operations commented: “We were thrilled to be selected to assist Bluewater in making these process and system improvements. The end results speak for themselves and provided a labor cost reduction and established a clear upgrade path for their CMMS system. We look forward to building on this success.”

If you would like to discuss the details of this project, please contact Tony Vaclavicek at tvaclavicek@genesissolutions.com

GenesisSolutions: Presentation Highlights 

ISPE (International Society of Pharmaceutical Engineering)

Mr. Michael Greenholtz, VP of Reliability Solutions will be presenting at the ISPE Tampa Conference on Thursday, February 25th at 8:30am.

The ISPE track is Beyond Book-learning: Practical Application of Good Engineering Practice and Maintenance Guides.

In addition, GenesisSolutions will be exhibiting Monday - Wednesday Feb 21-24 at table number 76 and can provide additional details on Mike’s presentation.

More information on the ISPE Tampa Conference is available at their website: www.ispe.org

MWMUG (Mountain West Maximo User Group)

Mr. Robert MacArthur, President of GenesisSolutions, presented at the Winter 2010 Meeting of the MWMUG hosted by the University of Utah on January 14th.

Rob’s presentation on Asset Reliability and Maintenance Program Improvements was very well received. Over 50 attendees participated in this mid-year meeting and the group will hold its annual conference this summer in Park City, Utah.

More information on the MWMUG is available at their website: www.mwmug.org

When: 1/14/10

The Mountain West Maximo Users Group was formed by Maximo users in the Utah and Rocky Mountain region.  We believe we are the only user group that is run by users.  We remember what it was like to walk down the aisles at MRO World/Pulse and wonder who should we talk to and who could really help us.  We have spent the last five years attending MRO World/Pulse and various user group meetings to build a network of users and vendors who really know how to help you.  Although we feel like we know how to move around in the Maximo community, we also look forward to meeting new and old users to share successes as well the horror stories.  That is what a user group is all about.

We are pleased to announce that Mike Greenholtz has joined GenesisSolutions in the role of Vice President - Reliability Solutions. Mike brings to Genesis a deep and broad background in all aspects of Maintenance and Reliability.  He will play a key role in growing the Reliability Services business and furthering the Genesis brand in this business segment. His responsibilities will also include strategic account development and management.

Mike began his career as a Plant Engineer and has served in positions of increasing responsibility in Engineering & Maintenance including utilities, facilities and operations. While holding the position of Assistant Vice President, Engineering & Maintenance for the Wyeth Pharmaceutical Operating Unit he led the global implementation of a leading-edge Maintenance Excellence program. His most recent position was Assistant Vice President, Engineering Operations at Wyeth. In that capacity his group provided Asset Lifecycle Management support for all Wyeth Operating Units.

Mike holds a BS in Mechanical Engineering from Virginia Polytechnic Institute in Blacksburg, VA.

Tom Terfehr, Partner & Executive Vice-President commented: “We are excited to have Mike join our team. After working in partnership with Mike and Wyeth for the past six years on their Maintenance Excellence program, we have developed the highest level of respect for Mike through our work together on strategic and tactical EAM systems and reliability efforts around the globe. We look forward to continuing our relationship with Mike, and his contributions here and for our customers.”

Mike Greenholtz added: “Over the past decade, the strategic partnership between GenesisSolutions and Wyeth has resulted in global supply chain reliability of life saving pharmaceuticals and vaccines. These results are remarkable and I am delighted to continue to serve in the Asset Management arena. I am excited to join GenesisSolutions and be part of this passionate and talented customer focused team that continues to achieve outstanding results for our customers.”

About GenesisSolutions

GenesisSolutions provides best-in-class maintenance and asset management to the world’s most sophisticated industrial organizations. We create operational and financial advantages for our customers by identifying and implementing measures that enhance asset reliability and increase capacity, while reducing maintenance costs and extending capital asset lifecycles.

GenesisSolutions is a privately held corporation with major investments from Seguin Partners and Ironwood Capital.

University of Delaware Completes Major Maximo 6.2 Implementation and Business Process Analysis 

The University of Delaware, in conjunction with GenesisSolutions, completed a major implementation of Maximo 6.2 on December 7^th 2009.  After thirteen months of dedicated and focused effort by the University and our consulting staff, a solid framework for a strategic Enterprise Asset Management program was completed.  Through an initial GAP Analysis and Business Process Definition (BPD), interfaces and existing best practices were mapped out in a phased approach to complete an out of the box Maximo 6.2 implementation.

The University team worked hand in hand with the Genesis consultants to make this project a success. Knowledge transfer, starting from day one, enabled the transition from Genesis to the University to go seamlessly. Technically, the advanced interface design took full advantage of standard Maximo capabilities and resulted in automated field functionality and validation. 

This successful implementation has set the stage for a wider acceptance of Maximo as an enterprise wide solution for the University.   In the coming months the University will be planning for the next phase of the implementation, including the following objectives: Mobile, Inventory and Purchasing, and a Time & Attendance Interface.

If you would like to discuss the details of this project, please contact V.J. Venkatraman at (410) 908-0790, or vvenkatraman@genesissolutions.com

GenesisSolutions a Presenter and Sponsor of IBM Pulse 2010 

GenesisSolutions, a leader in EAM Systems & Technology, Strategy & Process and Reliability Services, is proud to announce our participation as both a presenter and sponsor of the IBM Pulse 2010 conference.

Schedule of Presentations:

Sunday, February 21^st - 2:00pm - Airport Maximo User Group

Port of Seattle - Co-Presentation (Jim Oldach, Manager - Reliability Solutions)

“Putting Maximo Work History Data to Work”

Monday, February 22^nd  -  3:00pm - Exposition Theatre

Rob MacArthur, President of GenesisSolutions

“Enterprise Asset Management Life Cycle Maturity” 

Wednesday, February 24^th  - 8:00am - Breakout Session

Wyeth Pharmaceutical - Co-Presentation (Rob MacArthur)

“Implementing Maintenance Excellence - A Balanced Approach to Asset Management”

In addition to the presentation schedule, GenesisSolutions will be available at our conference booth.

Location:   Exposition Booth # S419

Date:         Sunday, Feb 21^st through Weds, Feb 24^th, 2010

Where:       MGM Grand in Las Vegas, Nevada.

Jim Oldach’s current role as GenesisSolutions Manager of Reliability Services focuses on developing technical solutions for its customers around maintenance and reliability improvement.  As his background in maintenance and operations began by “turning wrenches and valves” his approach to the business of reliability improvement is centered on impacting the person to machine interface.  A common statement he makes in his discussions is “Reliability doesn’t happen in a conference room, or within the CMMS, or during an RCM analysis, it happens when operators and maintainers operate and maintain the equipment.  If we’re not impacting that, we’re not doing our jobs.”

Jim began his engineering career as Ship’s Engineer in the U.S. Merchant Marine as a 1987 graduate of Massachusetts Maritime Academy.  Jim distinguished himself early in his Maritime career by graduating as Valedictorian of his class.  He spent the majority of his seagoing career working with an AT&T Transoceanic Cable ship in the business of installing fiber optic telephone cables all over the world.  His proudest billet was in support of Desert Storm logistics sailing on a Container / Crane ship transporting ordinance in the Persian Gulf. 
 
Jim transitioned to shore side engineering in 1992, entering into the Nuclear Power industry as an RCM analyst and has since spent the past 18 years as a Reliability and Maintenance contractor / consultant developing and managing reliability improvement projects across multiple industry verticals.  He has experience in power (nuclear, fossil, hydro), hospital facilities, water and wastewater, manufacturing, and pharmaceuticals.  Jim had the honor of being certified by John Moubray as a Certified Practitioner of Moubray’s RCM2 process and is also a Certified Maintenance and Reliability Professional (CMRP) through SMRP.

King County Wastewater Treatment - Maintenance & Reliability Improvement  

 In today’s environment of strained financial and human resources, whether in the private or public sector, the focus is to improve maintenance and reliability and it is of extreme importance to optimize the use of the limited maintenance resources. At King County Wastewater Treatment Division (KCWTD) in Seattle, the entire organization had the additional challenge of adding new facilities to expand its service capacity without adding maintenance resources.  Genesis was selected to partner with KCWTD to design and implement a comprehensive maintenance and reliability improvement project while also addressing the cost and resource constraint issues.  KCWTD expected a program based on cross-organization reliability and maintenance best practices.

The project scope included the following deliverables based on cross-organizational best practices:  
· Maintenance Work Management Reengineering
· Planning & Scheduling Training & Implementation
· Develop an Asset Lifecycle Management Framework
· Asset Criticality Analysis
· Reliability Engineering on Selected Critical Assets
· Preventive Maintenance Program Optimization
· CMMS upgrade/reconfiguration Functionality Enhancements
· An Organizational Change Management Plan including Training Delivery
· Metrics

The project began with documentation of the current state of core reliability and maintenance business processes. A gap analysis of current state versus leading-edge practices was conducted to identify opportunities to improve across the organization.  A clear and detailed plan of action including deliverables, timetables and metrics was developed. A few critical metrics, or Key Performance Indicators were identified and integrated into the program from the start.

A Maintenance Best Practices Steering Committee consisting of senior operating and maintenance management was formed to guide and support the program. Genesis was part of this core group throughout the project. This level of visibility and active support is a critical success factor in this type of improvement effort. This group used the Genesis Change Management Plan to guide its actions and evaluate progress. Providing time for personnel training in the new processes and methods was a critical success factor.

Implementation included substantial involvement of the entire maintenance organization. This included working sessions facilitated by Genesis to redesign maintenance work to become more effective and efficient. Training for all personnel involved in the redesigned processes was held. The maintenance planning & scheduling process was also redesigned. Genesis held a P&S training course for the P&S group and also introduced key stakeholders to the process to gain buy-in. Planning & Scheduling is a core reliability process and a major lever to improve reliability (move from reactive to proactive work) and increase maintenance craft efficiency.  By planning and scheduling work, wrench time can be increased from 30% (without planning) to 55% or higher (with planning) thereby almost doubling the amount of value added work completed by a work force. 

Reliability improvement had two other major components. First, a Criticality Analysis was done to bring focus to the maintenance program and tasks.  It is well documented that 10 - 15% of equipment assets consume more than 80% of the time, effort and cost in a reactive maintenance organization. Therefore, by identifying them and bringing the second component, Reliability Engineering, to bear on these assets repetitive failures can be drastically reduced improving reliability and providing maintenance crafts time to do other things. This two step approach resulted in lower maintenance and spare parts costs.

Further, it was identified that there was a substantial opportunity to reduce the amount of hours dedicated to the Preventive Maintenance program without increasing reliability risk. Genesis conducted a PM optimization effort that removed low value PM work, expanded the use of predictive technologies in place of time based PM, shifted some minor PM maintenance tasks to Operations, and optimized the use of labor resources via improved work packaging/scheduling.  The overall impact of the PMO is a reduction of approximately 4000 PM labor hours per year (45% of the original PM labor load), which equates to about 2.5 full time equivalent maintenance personnel.

Finally, when Planning & Scheduling was applied to the redesigned maintenance processes and focused on proactive work for the critical assets, wrench time improvements were the result. At project start KCWTD was planning and scheduling 40% of the labor hours.  At project completion, just over a year later, 90% of all work is being planned and scheduled.

Another critical success factor in any reliability program is the CMMS. In this case Genesis created the user requirements needed to support and enhance the maintenance & reliability best practices implementation. A functional requirements document was then created for use in the CMMS upgrade. These requirements included a few customized functions such as: additional spreadsheet-type data entry in maintenance shops, modifications to craft timesheet data entry to facilitate planning & scheduling and e-mail notifications to improve communication on work order status.

The GenesisSolutions reliability improvement approach  has been instrumental in supporting KCWTD’s efforts to provide more value, measured by reliability and cost, with the same amount of maintenance staff.  If you would like to discuss the details of this project, please contact Jim Oldach, Manager of Reliability Services, at joldach@genesissolutions.com or call 781-771-7817.

GenesisSolutions Sponsors Record Setting MUWG Conference
LCRA hosts 260 Maximo Utility Customers in Austin, TX

The Lower Colorado River Authority (LCRA) hosted the Fall 2009 Maximo Utility Working Group (MUWG) conference November 10th - 12th, 2009 in Austin, TX. The keynote presentation, delivered by V.J. George, CIO of LCRA, set the tone for the conference, “Managing Assets in the Smart World.”
 
The conference was attended by over 260 Maximo users in the power generation, distribution, transmission and water & wastewater utility industries. Organizations represented included Arizona Public Service, Austin Energy, International Power, LCRA, NRG Energy, SCANA, Southern Company, Spectra Energy, United States Army Corps of Engineers (USACE) and the United States Bureau of Reclamation (USBR).

IBM, the developer of the Maximo application, provided breakout workshops to the users on customer support initiatives, as well as development and functional updates. IBM also provided transportation for a tour of its local data center while LCRA provided a tour of its operations control headquarters.
 
Joe Pitman, Vice President of Customer Operations at GenesisSolutions, commented: “The Maximo Utility Working Group is one of the best industry conferences you can attend during the year. The free flow of information and networking available is a value that carries forward year-to-year. We are always excited about participating in this meeting, and this year it seemed to have more momentum than usual. The turnout and member presentations were exceptional.”
 
About the MUWG
 
The Maximo Utility Working Group (MUWG) is an industry group representing over 145 utility companies, counties and cities throughout the U.S., Canada, China, South Africa, Pakistan, Japan, and the Caribbean that exchange information related to the implementation and application of the Maximo asset management system. More information is available at www.muwg.org

As we come towards the end of 2009 I don’t think it is much of a stretch to think that most of us will not be unhappy to put this year behind us.  The economic challenges of the past 12-18 months have been unprecedented in most of our life times and had a negative impact on some of GenesisSolutions activities like that of almost all of our customers.  However, we weathered the storm intact and see calmer waters ahead with business activity and growth substantially picking back up in the 4th quarter.  We are hopeful that this is a positive indicator and points to further improvement in the global economy as well as for our customers.
 
As we complete 2009 GenesisSolutions will mark our 10-year anniversary of business and success.  We now count approximately 400 large industrial companies and organizations as customers.  Many of these have been customers for almost all ten years.  We are grateful for your business and trust.  We expect to earn it every day.
 
We believe the single most important factor to our success is our culture and business model.  This model includes three basic principles:
 
1. To be the preferred supplier of integrated end-to-end Enterprise Asset Management services to our customers.
2. To provide only the highest quality services and resources at a reasonable price.
3. To establish, nurture and grow long term trusting relationships with our customers.
 
We are growing again, deploying new services, expanding into new markets and geographies.   This newsletter will be a monthly publication in which we look to do a better job of keeping you, our customers, abreast of new developments at Genesis as well as a forum to foster EAM knowledge transfer to our customers.  This is a component of our updated customer outreach program.  Also please check out our new website at www.GenesisSolutions.com.  As always, feedback (good or bad) is appreciated.

GenesisSolutions Launches New Corporate Website 

GenesisSolutions is pleased to announce the launch of its newly redesigned website. The Company’s management team, employees and Board of Directors invite you to visit www.GenesisSolutions.com to see the new image of GenesisSolutions and learn about our recent accomplishments, current activities and complete summary of services offerings.
 
GenesisSolutions, founded in 1999, has provided enterprise asset management and asset reliability services to hundreds of industrial customers on a worldwide basis. Our services have helped increase production and reduce maintenance costs in industries including pharmaceuticals, biotech, energy, manufacturing, facilities and oil & gas.
 
“I love the new look of our website. It brings our strengths and capabilities into the open for current and prospective clients,” said Joe Pitman, Vice President of Customer Operations. “We like promoting our message of helping clients save money and this provides us with a direct outlet.”
 
Our new website provides our customer base and prospective clients with a clear picture of our experience and where we have helped our customers improve efficiencies.

GenesisSolutions & Wyeth Pharmaceuticals Team to Present on Maintenance Excellence at the Life Sciences Maximo User Conference

GenesisSolutions, in conjunction with Wyeth Pharmaceuticals, presented the results of a six year Maintenance Excellence initiative completed between the two firms targeting regulatory compliance, increased reliability, and ultimately cost optimization. The LSMUG conference was hosted by Abbott Laboratories in Lake County, Illinois on September 22nd & 23rd, 2009.

The title and theme of the presentation was: Reliability - Leveraging your Enterprise Asset Management (EAM) system investment for Maintenance Excellence.

Rob MacArthur, President of GenesisSolutions, along with Michael Greenholtz, Assistant Vice-President, Engineering Operations at Wyeth presented a 45 minute overview of the design, implementation and results of Wyeth’s Global Maintenance Excellence program.  This program was designed to leverage Wyeth’s significant investment in EAM / CMMS technology including Maximo and SAP PM in order to promote and foster a reliability driven maintenance culture across 40 plants worldwide.

The program focused upon an asset criticality driven maintenance strategy that targeted the implementation of reliability, planning and scheduling and critical inventory spares management in order to improve first run product quality rates, increase critical equipment uptime and decrease operating costs.  Results have included a 60% reduction in critical equipment maintenance related MIR’s (Manufacturing Incident Reports), a 40% reduction in unplanned downtime and 27% operating cost reduction in implemented areas.

Rob MacArthur commented, “The Wyeth Maintenance Excellence program is an example of a customer leveraging their investment in EAM systems technology to support actual business improvements.  This program is a realization of the original return-on-investment envisioned by most customers when they embark on EAM system selection and implementation.  These are real dollar savings and manufacturing improvements in critical life saving and quality of life drug product supply lines. GenesisSolutions is very proud to have been Wyeth’s global partner for this initiative and very pleased that we were able to share this experience with other life science customers at the LSMUG.”

GenesisSolutions Role and Responsibilities

GenesisSolutions helped design, implement and support the Wyeth Maintenance Excellence program on a worldwide basis working hand-in-hand with Wyeth Maintenance and Engineering personnel. GenesisSolutions support included:
· Program Design
· Global Site Assessments
· SAP PM, Maximo and CalMan CCMS implementation and Optimization
· Asset Criticality Assessments
· Asset FMEA, Maintenance Strategy Planning and PM Optimization
· Critical Spare Parts program design
· Calibration Program Optimization
· Automation & Controls interface
· Global Predictive Maintenance Program design & implementation
· Key Performance Indicator Measurements
· Site Training
 
About the Life Sciences Maximo User Group (LSMUG)

The LSMUG conference is a biannual meeting of companies in Life Sciences, Healthcare and Regulatory Industries that use Maximo Asset Management with focused interests in networking, sharing asset services and maintenance best practices in the use of the Maximo application suite. The group also provides feedback information and experiences on how to best implement and use new functionality which is shared with peers as well as the IBM solution development team.

About the Maintenance Excellence initiative at Wyeth Pharmaceuticals

The vision is to provide a competitive advantage for Wyeth Operations by establishing and utilizing “the Best” Maintenance Practices to improve Facility and Equipment Reliability, Operating Life and Efficiency in the most cost effective manner possible while enhancing Regulatory Compliance.

The key components include: Proactive maintenance, work force management, supply chain optimization, technology & data management and finally, performance management.

About GenesisSolutions 

GenesisSolutions provides best-in-class maintenance and asset management to the world’s most sophisticated industrial organizations. We create operational and financial advantages for our customers by identifying and implementing measures that enhance asset reliability and increase capacity, while reducing maintenance costs and extending capital asset lifecycles.

GenesisSolutions is a privately held corporation with major investments from Seguin Partners and Ironwood Capital.

When: 10/23/09

The Rocky Mountain Maximo User Group is a forum for networking with professionals in the Rocky Mountain area, picking up Maximo tips and driving the most value from your Maximo investment. The group meets about 3 times a year face-to-face and there is a discussion board to facilitate virtual networking.

When: 10/21/09

The primary purpose of the Southern California MAXIMO Users’ Group (SCMUG) is to provide an open forum for the discussion of technical and business issues involved with the employment of the MAXIMO product line of maintenance, production, fleet and asset management systems. The SCMUG values the personal and professional opinions of all types of MAXIMO users, from the Operational and Technical Management through the end users of the data systems.

Meetings are twice yearly.

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.