The Company
Nationwide Sports Drink Bottler
The Situation
A leading, nationwide sports drink bottler was struggling to keep up with maintenance requirements for their numerous pieces of equipment. In addition, their maintenance shop and storeroom were functionally inadequate to effectively maintain the asset base in the plant.
The Scope
Focus Operations Consulting Group was engaged to develop and implement the Company’s Asset Reliability Model with a view to providing a world class maintenance organization, as well as to completely redesign and set up the storeroom and maintenance shop.
Focus OCG Action
A Focus OCG senior consultant developed the Company’s Asset Reliability Model with a cross-functional team from the plant and integrated the process with the CMMS (Computerized Maintenance Management System) to provide the maintenance organization with the best processes to manage, plan, schedule and maintain the entire asset base in the facility. This process integration included implementing equipment strategies with interactive PM routines, a technical library, equipment component identification, and parts and maintenance project management. The processes were integrated into the current operational improvement plan and provided best practices for the plant and other sister plants throughout the country.
A second consultant met with the maintenance and procurement team and together developed a world class storeroom and maintenance shop which fully integrated into both the Asset Reliability Model and the CMMS. A step-by-step change process was implemented, and a critical path chart was created and updated daily as progress was made. All parts were profiled for the correct part number and association with the correct piece or type of equipment, labeled, bar coded, entered into the CMMS, given a min and max quantity and stored in appropriate locations.
Results
With expertise of Focus OCG consultants, the client was able to effectively maintain the asset base in their facility, track all activities, sharply reduce equipment downtime and repetitive problems and minimize the impact of maintenance in the 24/7 operation. In addition, the plant had a fully functional storeroom, which significantly reduced part overstocks, downtime and overnight freight costs.
Another key result was the ability of the plant to track all part usage by equipment component and cost associated with repairs. Vendor activity and service was also tracked and given key service performance indicators.
The maintenance organization also became highly effective in the newly-designed and newly-located maintenance shop with the correct amount of space, equipment and access to both the plant and technical information to make repairs.
As a result of Focus OCG involvement, this plant became the flag ship example for reliability processes and storeroom and maintenance shop organization and functionality in the beverage division.
