mcp consul*ng group limited amis - iama · • storekeeper ... • ownership of workplace processes...

MCP Consul*ng Group Limited AMIS

Febuary 2017 Richard Fathers [email protected]

© MCP Consul@ng & Training Ltd 2016. Not to be reproduced without permission – Slide No. 2

MCP Creden*als

•  Est. 1987 •  30 staff in UK •  20 staff in Europe •  50 associates worldwide •  Partners in other disciplines

•  Support our clients with Consul@ng & Training in: Manufacturing, Maintenance, Asset Management •  Specialise in Food & Drink, Facili@es, Pharmaceu@cal

Automo@ve •  Chemical, Power •  Links with CMMS suppliers -‐ Maximo, SAP, Mainsaver

UK Solihull, W Midlands, Reading, Derby

Europe Spain, Portugal Sweden, Austria, Germany

N America: USA Chicago Canada: Toronto

Middle East Abu Dhabi, Jordan

China

Focus is

High Risk, High Impact organisa*ons


MCP Customers


What is AMIS?

AMIS

Asset Management Improvement System incorporates a benchmarking tool

Developed in UK by MCP; used by 4000 sites worldwide to improve maintenance (Asset Management)

Based on Best Practice

Standard approach to ensure consistency


AMIS Background

•  Assessment of maintenance practices, systems, methods •  Based on a best practice model for asset management •  Use Self-appraisal process •  Benchmark to external best practice •  Comparison with >4000 audits worldwide •  Sector specific comparisons •  Average 1st time assessment score 20-30% •  Target: World Class status > 75%


MCP’s 4 Stage Approach for Improvement

Stage 1 Benchmarking & Assessment

Stage 2 Implementa@on planning

Stage 3 Implementa@on

Find the gaps against best prac@ce standard using AMIS

Design the business processes and systems that will support the desired change

Train / Support / Coach

Stage 4 Review Plan Check and audit


AMIS Categories & Focus Areas

Assess how well the asset care strategy is driving the key areas of:

1. General Maintenance 2. Organisa@on 3. Work Planning 4. Cost Management 5. Produc@vity & Effec@veness 6. Materials Management 7. Failure Analysis & C.I. 8. Training & Safety

1

2

3

4

5

6

7

8


Audit Programme 1 -‐ (3 days on-‐site)

•  Assessment by representa@ve team of company’s engineers and produc@on people

•  Review Organisa@on & Maintenance data (Part I Ques@onnaire ) •  Self assessment to AMIS standard (Part 2 Ques@onnaire ) •  Plant tour •  Teams use Ques@onnaires for Produc@on and Maintenance staff

survey •  Collect data on maintenance and manufacturing performance •  Develop ideas and ac@ons •  Calculate scores •  Iden@fy opportuni@es for improvement •  Brainstorming to develop ac@on plans •  Feedback to site management •  Summary Report


Team Composi*on – Typical

•  Engineering Manager •  Engineering Team Leader/ Supervisors •  Process Engineers •  Operators •  Technicians •  Maintenance Planner •  Storekeeper •  Training Manager •  Produc@on Manager/ Supervisor •  Con@nuous Improvement Champion •  Team members spend all the day 1 together @me plus some @me on

each remaining day •  Core group selected to spend all the @me with MCP assessor •  Assessment is site led supported by MCP


AMIS Aquatera Results

AllMAINTENANCE MANAGEMENT Max Sectors

Ave%

1. General Maintenance Level 75 67 28 64 96 532. Organisation and Administration 100 51 29 56 92 263. Workload Planning and Control 250 42 0 49 98 184. Cost Management 125 33 0 28 82 25. Productivity and Maintenance Effectiveness 150 42 9 43 99 266. Materials Management 100 58 2 48 95 77. Failure Analysis and Betterment 150 41 15 40 85 128. T raining and Safety 50 57 10 54 92 68

47 9 52 97 2641 10 42 88 1944 2 37 83 424 24 56 89 4046 16 46 86 21

PLANNING INDEXEFFECTIVENESS INDEXCOST INDEXORGANISATION INDEXOVERALL EFFECTIVENESS INDEX

AquateraWater Sector ScoresCATEGORY Points Low

%Average

%High

%


Results by Management Category


Industry Comparison


• Strategy • Aligned Organisation

• Safe Working

• Work Recording

• Planned Preventive

Maintenance

• Correct Maintenance

Skills

• Work Place Organisation

• Team Working

• Assets In Maintainable

Condition

• Work Planning

• Maintenance Cost

Recording

• Critical Equipment &

spares

• Spares Provisioning

• Admin and Support

• Standard Jobs

• Cost Accountability

• Work Scheduling

• Asset History

• Operator Asset Care

• MaintenancMetrics & Reports

• Maintenanc Cost

Prediction

• Aligned responsibilities

• Succession Succession

Planning • High Labour

Utilisation

• New Equipment

Management

• Reliability Engineering

• Life Cycle Costing

• Continuous Improvement

• Reliable Equipment &

Processes

• Performing, motivated teams

• World Class Performance

Aquatera Pyramid


Aquatera Journey to World Class


37% 53%

65%

74% 81%

86%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

2015 2016 2017 2018 2019 2020

AMIS % AMIS Projec*on

Actual Projec@on World Class

Exceptional Plant Performance

Asset Care Excellence

World Class Processes

High benefits as all people engaged

Maintenance Excellence

Limited benefits as ~60 people

engaged


Opera*ng Excellence Depends on….3 things…

Operation 40-50% •  OBW to Operate •  Adherence to OBW •  Operator Asset Care Preventing failures •  OEE •  CI activities •  Skills and Training

THE ORGANISATION WANTS Highest Possible Equipment, Building and People Reliability

Design 30-40% •  Fit for purpose •  DO opportunities •  Built in reliability •  Ease of Operation •  Ease of Maintenance •  CI modifications

Maintenance 10-30% •  Risk Management •  FMECA / RCM •  Maintenance Plans •  Delivery of Plans •  Maintainability •  CI activities

DOERS NEED THE BEST SUPPORT SYSTEMS, DATA AND PROCEDURES


2017


2017 All

MAINTENANCE MANAGEMENT Max SectorsAve%

1. General Maintenance Level 75 67 28 64 96 762. Organisation and Administration 100 51 29 56 92 583. Workload Planning and Control 250 42 0 49 98 324. Cost Management 125 33 0 28 82 225. Productivity and Maintenance Effectiveness 150 42 9 43 99 406. Materials Management 100 58 2 48 95 497. Failure Analysis and Betterment 150 41 15 40 85 418. T raining and Safety 50 57 10 54 92 82

47 9 52 97 4241 10 42 88 4044 2 37 83 3424 24 56 89 6646 16 46 86 44

AquateraWater Sector ScoresCATEGORY Points Low

%Average

%High

%

PLANNING INDEXEFFECTIVENESS INDEXCOST INDEXORGANISATION INDEXOVERALL EFFECTIVENESS INDEX


Typically Implemen*ng An Asset Care Strategy Would Provide The Following Range Of Benefits : •  Lower cost of repairs – fewer spares and less time •  Fewer surprise breakdowns and risks to supplying customers •  Less catch-up time on overtime •  Better equipment reliability from Risk Based Maintenance •  Release of equipment capacity – able to delay future investment

needs •  Maintenance involvement in equipment selection – lower life cycle

costs •  More sensitive operation of equipment •  Better man-power utilisation – avoiding delays •  Fewer rejects, less waste, more yield from materials •  Operators doing 1st level maintenance – ownership of equipment •  Technicians released to do diagnostic work – longer term •  All employees following the same strategy guideline


Benefits Con*nued: •  Improved equipment set-up leading to….

§  lower energy usage §  improved quality §  more reliable performance

•  Improved morale – Asset Care seen as a positive contribution to business performance

•  Ownership of workplace processes and KPI’s leading to a CI culture and business savings

Training that provides the tools and techniques is considered a vital pillar No training – No knowledge – No improvement – No business !!

Typically form an average position, cost savings of 20% of current expenditure is considered to be obtainable over say the next 2 - 3 years. Successful CI activity could (and should) exceed this figure.


Examples : But What Could You Achieve?

Produc@vity Increased by 20%

Manufacturing Costs Reduced by 20%

Quality Costs Reduced by 30%

Maintenance Costs Reduced by 20%

Performance/Efficiency Greater than 85%

Number of Breakdowns Reduced by 50%

Number of CI Sugges@ons Increased by 500%

Workforce Involvement Greater than 80%

Number of Accidents Reduced by 50%

© MCP Consul@ng Ltd. 2016. Not to be reproduced without permission – Slide No. 22

Thank you Any Ques*ons?

Thank you

MCP: +44 (0) 121 506 9032 email: [email protected] visit: www.mcpeurope.com

mcp consul*ng group limited amis - iama · • storekeeper ... • ownership of workplace processes...

Documents