Peter Gagg, managing director, MCP Consulting and Training
Justifying the amount spent on maintaining your company’s physical assets has always been an uphill struggle which is even more difficult in times of economic slowdown. Requests for capital, for example; a new computer system, more technicians, predictive maintenance technology tools, all cost thousands of pounds but don’t actually produce anything which generates sales revenue are even harder to justify.
Senior management rarely appreciate the contribution of the maintenance department to the business, and often see it as a drain on valuable resources. As a maintenance professional you should ask yourself the following questions:
How can we demonstrate we are providing value for money
How can we improve what we do
How can we give a better service to production
How can we demonstrate a return on investment in new technology and CMMS systems
What are they key issues within maintenance in my company
How do we compare to other companies in terms of performance and efficiency
How much better could we be
What is the scope for delivering greater benefits to the business
All of these questions can be answered by assessing, revieiwing and benchmarking your maintenance. (MCP’s AMIS - AMIS Asset Management Improvement Service is one example. AMIS has been revised and upgraded to provide a comprehensive review of maintenance within any organisation.)
Based on the success of the original DTI sponsored AMIS audit, MCP have developed the process to meet the requirements of today’s maintenance and business environment and the requirements of the proposed ISO 55000 standard for physical asset management. AMIS assists and guides companies to develop best practices in asset management with the focus on driving improvements and benefits, whilst supporting the requirements of ISO (PAS 55).
During the past few years companies have changed their methods of working, often driven by the implementation of a computer software package (CMMS), organisation structure or maintenance approach but few companies know how effective they are or what they can do with their existing systems to help increase efficiency. In many companies changing the culture and behaviour of people is the critical factor. The best systems ever developed will not work if the people are not behind them or can’t see the benefits.
MCP’s AMIS addresses all of the problems and more with a comprehensive review process over a three-day period. Developed and fully tested in the USA and UK the new service can be shown to deliver real bottom line benefits that will please even the toughest finance director.
How does AMIS work?
The objective of the AMIS process is to enable management to carry out a facilitated, structured, self-appraisal of their management systems, methods, organisation and technology, using a team-based approach usually over a three-day period. Actual timescale will depend on the particular site and the requirements.
A typical team will comprise; maintenance manager, maintenance and production representatives, reliability engineers, stores and maintenance planners/CMMS administrators. The review process is driven by a trained facilitator using a standard set of questions, covering a range of topics.
After completing the questionnaire section the team and facilitator will work together to:
Determine plant performance improvements
Assess the culture and motivational issues
Identify and agree areas for improvement
Review the use of the CMMS, spare parts management contactor management etc
Develop a series of prioritised actions which will deliver business benefits
The results of the review are summarised in a series of tables and charts which provide:
A series of performance scores (Figures 1a & 1b)
A series of key performance measures (Figure 2)
In summary the AMIS process provides an independent external review of a company’s maintenance strengths, efficiency and scope for improvement in a cost effective manner.
Substantial benefits have been reported by companies across the world in a wide range of industry sectors, some of which are shown Figure 3.
“MCP has worked with our sites worldwide helping us deliver break-through benefits in our manufacturing facilities using the AMIS methodology.”
Johnson and Johnson
Some typical benefits are:
Maintenance cost reduced by up to 10%
Preventive maintenance programme revised eliminating up to 30% of existing tasks
Spare parts stock reduced by 15-20%
Plant performance increased typically by 30% but can be up to 100%!”
MCP has also recently launched an extended AMIS product, FMScan, which is designed to assess performance in facilities management covering both hard and soft services. This ensures that the original AMIS product is meeting the needs of asset managers in all sectors of business.
The AMIS Club
In conjunction with Maintenance Engineering magazine, MCP are establishing the AMIS Benchmarking club which will promote the delivery of world-class asset management. Regular articles and features will be published and access to world-class factories will be arranged for members through the AMIS Masterclass series.
Participating members will also be able to provide data and information online which will be used to calculate a series of industry specific Key Performance Ratios similar to those shown in Figure 2, which will be shared with all members.
Regular awareness and workshops to assist companies in achieving PAS 55 certification will also be provide at a subsidised rate.
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