In the case study, the challenge was the excessively high downtime, inspections being completed by hand, inconsistent responses and fault identification, limited data capture only when deemed necessary, and the lack of comprehensive trend analysis on asset condition, performance, and expenditure. The solution involved developing a reliability charter and a consolidated maintenance strategy aligned with Reliability Centred Maintenance principles. Guided electronic inspection solutions were implemented to ensure detailed capture of all maintenance activities. An analytics and reporting platform was utilised to identify abnormalities, trends, and opportunities for improvement. The key outcomes included an approximate 50% reduction in paper usage for conveyor maintenance activities, an 18% increase in conveyor availability, improved transparency and understanding of asset and contract performance, and ongoing opportunities to enhance production, availability, costs, and safety.
The Challenge
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- Downtime was excessively high
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- Inspections were completed by hand
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- Responses and fault identification varied
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- Data only captured when inspector believed the fault/failure required attention
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- Limited trend analysis on asset condition, performance, and expenditure
The Solution
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- Developed reliability charter and consolidated maintenance strategy aligned with Reliability Centred Maintenance principles
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- Guided electronic inspection solutions
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- Detailed capture of all maintenance activities
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- Analytics and reporting platform to identify abnormalities, trends and improvements
Key Outcomes
Less paper used
Approx. 50% reduction of paper used in conveyer maintenance activities
More conveyor availability
18% increase in conveyor availability
Better performance monitoring
Increased transparency & understanding of asset & contract performance
Continuous improvement
Continued opportunities to improve production, availability, costs & safety
