In the case study, the challenge was the use of antiquated systems and processes by site personnel, the ERP system not providing detailed information for decision making, a lack of credible data for issue recognition and process improvement, and the significant impact of conveyor systems’ availability on production. Additionally, the budget and forecasting ability was rudimentary. The solution involved conducting a comprehensive plant audit for the conveyor system, implementing an electronic inspection system, and adopting a cloud-based solution for real-time information access. Weekly and monthly reporting on reliability, production costs, and safety issues were implemented, and maintenance expenditure was meticulously tracked. The key outcomes included a daily understanding of asset condition, reduction in equipment-related downtime, increased transparency of conveyor system performance, improved availability, and a demonstrable reduction in production costs.
The Challenge
- Site personnel using antiquated systems and processes
- ERP not delivering finite information for decision making
- No credible data to recognise issues and zero processes for improvement
- Conveyor systems’ availability was dramatically affecting production
- Budget and forecasting ability extremely rudimentary
The Solution
- Completed comprehensive plant audit for conveyor system
- Implemented electronic inspection system
- Cloud-based solution for real-time information access
- Weekly and monthly reporting on reliability, production costs, and safety issues
- Maintenance expenditure tracked across site down to the “nut and bolt”
Key Outcomes
Asset tracking
Daily understanding of asset condition
Reduced downtime
Reduction in equipment-related downtime
Better metrics
Increased transparency of conveyor system performance
Less production costs
Increased availability and a demonstrable reduction in production costs
