Factory Objectives Value of Asset Management Strategies.

Factory ObjectivesFactory Objectives

• Value of Asset Management Strategies • Value of Asset Management Strategies

Factory ObjectivesFactory Objectives

Controlling ProductivityControlling ProductivityControlling ProductivityControlling Productivity

Avoiding Quality Avoiding Quality IssuesIssues


Complying With Regulations Requiring Audit TrailsComplying With Regulations Requiring Audit TrailsComplying With Regulations Requiring Audit TrailsComplying With Regulations Requiring Audit Trails

Improving Productivity of Indirect LaborImproving Productivity of Indirect LaborImproving Productivity of Indirect LaborImproving Productivity of Indirect Labor

Reducing Commissioning Time & CostReducing Commissioning Time & CostReducing Commissioning Time & CostReducing Commissioning Time & Cost

Keeping Employees SafeKeeping Employees SafeKeeping Employees SafeKeeping Employees Safe

Disaster Disaster RecoveryRecovery


Assets Influence on Factory ObjectivesAssets Influence on Factory Objectives

What concerns you…What concerns you…










Controlling ProductivityControlling Productivity

• Case: Home Care Products ManufacturerCase: Home Care Products Manufacturer– Production constraints forced us to keep the line running. As a Production constraints forced us to keep the line running. As a

result, when the there was a problem, maintenance inserted a result, when the there was a problem, maintenance inserted a “patch” to the asset configuration, which is only designed to “patch” to the asset configuration, which is only designed to temporarily fix the problem. temporarily fix the problem.

• Consequence: Consequence: – Eventually the “patch” was not enough to keep the line Eventually the “patch” was not enough to keep the line

running. The original problem became a major problem. The running. The original problem became a major problem. The line was down for hours before they could get it back up and line was down for hours before they could get it back up and running.running.

• Solution: Solution: – Automatically tracking all changes to asset configurations and Automatically tracking all changes to asset configurations and

knowing who made the change, allows the manager to find out knowing who made the change, allows the manager to find out the reason for the change and can schedule work to fix the the reason for the change and can schedule work to fix the problem when there is less of an impact. problem when there is less of an impact.

• Benefits:Benefits:– Lower production cost and better overall delivery times.Lower production cost and better overall delivery times.– Provide reliable change management to efficiently manage Provide reliable change management to efficiently manage

assets.assets.

Disaster RecoveryDisaster Recovery

• Case: Pet Food ManufacturerCase: Pet Food Manufacturer– Computer maintenance lost programs on several key assets. In Computer maintenance lost programs on several key assets. In

spite of manually saving programs on a central server, they spite of manually saving programs on a central server, they ended up using a very old version made by the OEM of the ended up using a very old version made by the OEM of the machine.machine.

• Consequences: Consequences: – Hours of downtime and lost production to be made up with Hours of downtime and lost production to be made up with

overtime.overtime.– Extra cost of indirect labor for remaking the asset Extra cost of indirect labor for remaking the asset

configurations.configurations.• Solution: Solution:

– By managing asset configuration versions automatically in a By managing asset configuration versions automatically in a central repository and by automatically backing them up, no central repository and by automatically backing them up, no program is lost. As well, through version control, everyone program is lost. As well, through version control, everyone knows which program to use immediately.knows which program to use immediately.

• Benefits: Benefits: – Save production cost and delivery time issues by always Save production cost and delivery time issues by always

knowing which program is the right version.knowing which program is the right version.– Provide confidence in the process and controller program for Provide confidence in the process and controller program for

the engineering and maintenance teams.the engineering and maintenance teams.

Avoiding Quality IssuesAvoiding Quality Issues

• Case: Olive Oil ManufacturerCase: Olive Oil Manufacturer– An annual maintenance review showed that some sensors An annual maintenance review showed that some sensors

needed to be replaced. After several weeks, customers started to needed to be replaced. After several weeks, customers started to complain about poorly sealed bottles. After investigation, complain about poorly sealed bottles. After investigation, someone discovered the faulty wiring of the sensor, which someone discovered the faulty wiring of the sensor, which resulted in the poorly sealed bottles.resulted in the poorly sealed bottles.

• Consequences: Consequences: – Reimbursement for the affected customers causing the company Reimbursement for the affected customers causing the company

additional expense. additional expense. – Several weeks’ production stock was fully inspected at additional Several weeks’ production stock was fully inspected at additional

costs, in order to identify poorly sealed bottlescosts, in order to identify poorly sealed bottles..• Solution: Solution:

– By regularly collecting diagnostics of devices and displaying the By regularly collecting diagnostics of devices and displaying the status and troubleshooting information to the maintenance team status and troubleshooting information to the maintenance team makes them immediately aware of the problem. This information makes them immediately aware of the problem. This information includes details on how to fix the problem, and in many includes details on how to fix the problem, and in many instances, the maintenance team can take action before the instances, the maintenance team can take action before the problem actually occurs, thereby avoiding downtime.problem actually occurs, thereby avoiding downtime.

• Benefits: Benefits: – Line stays up and running to maintain continuous production and Line stays up and running to maintain continuous production and

to potentially avoid an incident in the first place.to potentially avoid an incident in the first place.– More effective use of the maintenance teamMore effective use of the maintenance team..– Scrap reduction.Scrap reduction.

Regulation & Audit Trail IssuesRegulation & Audit Trail Issues

• Case: Pharmaceutical CompanyCase: Pharmaceutical Company– It is a requirement to maintain an audit trail of their It is a requirement to maintain an audit trail of their

production, including actions performed on assets. In order to production, including actions performed on assets. In order to comply with this requirement, the company maintains a comply with this requirement, the company maintains a manual process whereby all engineers are required to manual process whereby all engineers are required to complete documentation for every change. complete documentation for every change.

• Consequences: Consequences: – Inconsistent quality of change documentation.Inconsistent quality of change documentation.– They already had troubles due to non tracked changes in spite They already had troubles due to non tracked changes in spite

of the internal manual procedure.of the internal manual procedure.• Solution: Solution:

– By automatically tracking each change, the company can be By automatically tracking each change, the company can be sure it has not missed any changes automatically. Engineers sure it has not missed any changes automatically. Engineers no longer have to manually prepare the change no longer have to manually prepare the change documentation. documentation.

• Benefits: Benefits: – Certain compliance with audit requirements. Certain compliance with audit requirements. – Prevent mistakes being made by unskilled or untrained Prevent mistakes being made by unskilled or untrained

individuals.individuals.

Indirect Labor IssuesIndirect Labor Issues

• Case: Oil & Gas Distribution BusinessCase: Oil & Gas Distribution Business– Periodically an engineer is tasked with taking machine Periodically an engineer is tasked with taking machine

analysis readings at several locations for preventive analysis readings at several locations for preventive maintenance. It takes almost a week to get the readings maintenance. It takes almost a week to get the readings from each location, and then the analysis is performed from each location, and then the analysis is performed and decisions made about the data. and decisions made about the data.

• Consequences: Consequences: – Waste of a valuable resource who provides no added Waste of a valuable resource who provides no added

value compared to what this skilled person could do for value compared to what this skilled person could do for improving productivity and maintaining equipment.improving productivity and maintaining equipment.

• Solutions: Solutions: – By automatically gathering and analyzing (against By automatically gathering and analyzing (against

standards) the readings from the machinery, the standards) the readings from the machinery, the engineer is used for more valuable tasks.engineer is used for more valuable tasks.

• Benefits: Benefits: – Increase productivity of human capitalIncrease productivity of human capital– Better analysis and consistent decisions about dataBetter analysis and consistent decisions about data– Decrease cost of indirect laborDecrease cost of indirect labor

Indirect Labor IssuesIndirect Labor Issues

• Case: Assembly LineCase: Assembly Line– We put in a computer maintenance management system in We put in a computer maintenance management system in

several years ago to track work and spare part usage. several years ago to track work and spare part usage. Unfortunately, when the line stops, no one wants to take any Unfortunately, when the line stops, no one wants to take any time to enter a work order and afterwards no one seems to time to enter a work order and afterwards no one seems to identify what the root cause was and what was used to fix it. identify what the root cause was and what was used to fix it.

• Consequences: Consequences: – Inconsistent root cause and spare parts usage data. Inconsistent root cause and spare parts usage data. – Management can not make needed decisions about Management can not make needed decisions about

maintenance because data is unreliable. maintenance because data is unreliable. • Solutions: Solutions:

– By automatically gathering work orders from the machinery By automatically gathering work orders from the machinery directly, no time is wasted by maintenance to get to the directly, no time is wasted by maintenance to get to the actual problem. Since the work orders exist, it is much easier actual problem. Since the work orders exist, it is much easier to track root cause and usage. to track root cause and usage.

• Benefits: Benefits: – Increase productivity of human capitalIncrease productivity of human capital– Better analysis and consistent decisions about dataBetter analysis and consistent decisions about data– Decrease cost of indirect laborDecrease cost of indirect labor– Less spare parts inventoryLess spare parts inventory

Commissioning IssuesCommissioning Issues

• Case: Consumer Product ManufacturerCase: Consumer Product Manufacturer– During commissioning of a line, one team would write over During commissioning of a line, one team would write over

another teams valuable changes. another teams valuable changes. • Consequences: Consequences:

– Commissioning took considerably longer.Commissioning took considerably longer.– Project cost increased & delayed releasing new product to Project cost increased & delayed releasing new product to

market.market.• Solutions: Solutions:

– By allocating individual access rights to assets and By allocating individual access rights to assets and configuration tool functions, they are able to contain one team configuration tool functions, they are able to contain one team to certain tasks and devices avoiding rework.to certain tasks and devices avoiding rework.

– By tracking changes, the two teams were able to understand By tracking changes, the two teams were able to understand what and why changes were made and by who. As well, the what and why changes were made and by who. As well, the most recent program was always available, as well as a most recent program was always available, as well as a complete version history, in the event an inadvertent change complete version history, in the event an inadvertent change was made.was made.

• Benefits: Benefits: – Reduce time to market and costs with quicker commissioning Reduce time to market and costs with quicker commissioning

due to collaboration between the teams. due to collaboration between the teams.

Employee SafetyEmployee Safety

• Case: Metal ManufacturerCase: Metal Manufacturer– Someone performed several configuration changes to assets Someone performed several configuration changes to assets

associated with a production machine. Changes were intended associated with a production machine. Changes were intended to be temporary, and consequently were not documented. to be temporary, and consequently were not documented. Because the changes were not to be permanent, testing to Because the changes were not to be permanent, testing to insure that no security or safety risks existed did not take place.insure that no security or safety risks existed did not take place.

• Consequences: Consequences: – An operator had serious injuries.An operator had serious injuries.

• Solutions:Solutions: – By tracking changes, the customer now is able to check By tracking changes, the customer now is able to check

regularly what changes, if any, were performed by who and regularly what changes, if any, were performed by who and when. It is now possible to discover the changes and insure they when. It is now possible to discover the changes and insure they are compliant with security rules and if they are not permanent, are compliant with security rules and if they are not permanent, check if they were removed.check if they were removed.

• Benefits:Benefits: – Prevent injuries to employees, contractors, visitors, and other in Prevent injuries to employees, contractors, visitors, and other in

the plant.the plant.

RSMACC solving plant floor problems… RSMACC solving plant floor problems…










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Factory Objectives Value of Asset Management Strategies.

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