South American PVC Plant Optimizes Maintenance Efficiency
An international chemical company wanted to optimize their maintenance management processes at a South American PVC plant. Although the plant had an annual maintenance budget of approximately €13 million there were irregular patterns of expenditures, sloppy inventory management, and rising salary costs, which were higher than their European partners. T.A. Cook was selected to conduct a three-week analysis program of the 175,000 square meter plant, with two units for PVC manufacturing and one unit for chemicals. Here are the key results:
Approach
The analysis revealed that there were a multitude of issues in
planning and monitoring, stemming from passive management. To
address maintenance performance, the consultants implemented new
management tools for planning and job preparation. Norms and
standards were created and communicated to optimize worker
efficiency and ensure work order creations. Finally, a gate-keeping
process was created to allow for stronger prioritization. To enhance
supervision, staff were robustly organized with clearly defined
performance goals. Defined methodology was implemented and all
training and coaching the maintenance staff may need was provided. A
“standard” day framework for expectations and maintenance technician
behaviour was developed. Daily, weekly and monthly performance
review meetings were scheduled. Finally, a process to evaluate
contractors’ performance based on safety, quality and price was
implemented.
Practical solutions were put in place to increase maintenance
productivity. First, a preventive maintenance plan for clarification
of tasks was established. Then, a system for analysis of breakdowns
and their reasons and agreement of future preventive action was put
in place. Finally, the company SAP software was updated and
employees were trained.
Achievements
Following the creation of a capable maintenance team with clearly defined responsibilities and schedules, a system of accountability and proactive supervision was created and significant financial benefits and costs savings were enjoyed.