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.
Reliability Services: Large Nutritionals Plant
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:
Results Achieved