Operations and maintenance personnel unite to improve efficiency and reliability using ARMS Reliability's OnePM® process to leverage improvements worldwide.
The medical device manufacturer uncovered $150 million in cost-savings over 10 years for a single machine at a single facility.
Our client, a global medical and pharmaceutical device company, had an important, intricate manufacturing machine they suspected was underperforming - it was frequently down, causing decreased production and increasing emergency and corrective labor costs. With many of these same machines operating at facilities around the world, the company needed to know why they were often unavailable, and the best way to improve their performance.
The medical device company called on ARMS Reliability to assess the problem and offer maintenance-strategy solutions. Working together as partners with company team members at a single site, we conducted a Reliability Centered Maintenance [RCM] study on the machine, optimizing maintenance activities and frequencies for performance improvement.
ARMS Reliability was charged with completing a study to risk-optimize the maintenance strategies for 40 asset types at this location; we ultimately completed multiple asset types within 53 machine stations, as well as another 32 shared assets.
ARMS Reliability's RCM study provided our client with a quantified new maintenance strategy expected to save this single facility more than $15 million a year for ten years - a 91% cost savings over the current strategy. The new optimized maintenance strategy will also reduce machine downtime, labor allocation, and idle time.
Our team-based approach meant bringing company operations, directors, and management to the table along with reliability and maintenance professionals. This inclusive practice facilitated free-flowing communication, illuminated new blind spots, and helped personnel begin to think of themselves as reliability implementers.
We also invited key team members from other company sites around the world that have the same machine in their plants to collectively participate in using the same approach to improve their own maintenance strategies. Not only can the pilot site use the same model to identify other opportunities for performance improvement, but other global locations can leverage this data and these results to improve performance at their own facilities - potentially multiplying the benefits of this maintenance-strategy optimization many times over company-wide.