Food Manufacturing, Engineering & Consulting Case Study

Industry

Food Manufacturing

Location

Midwest U.S.

Support

Engineering & Consulting Services

Initial Involvement: A multi-billion dollar food manufacturer used a reactive approach to maintenance - allowing assets to run until failure before maintenance stepped in. Although maintenance team members were great “firefighters,” the approach failed to improve plant reliability. Realizing in order to change from a reactive to proactive plant, the manufacturer invested in an asset management system. But, as with any change, there was significant resistance and the implementation ultimately failed. Disconnect between maintenance and the MRO / indirect materials storeroom was a major limiting factor for success. A second initiative, this time involving the third-party MRO integrated plant services provider, was launched and backed by the company’s leadership team.

Added Value: Synovos worked with those key leaders to tie storeroom operations into asset reliability and master data leadership. This time, the goal was expanded beyond asset performance to include overall maintenance effectiveness. It was a decision that directly affected overall plant performance. A set of objectives and key performance indicators were established, the site was benchmarked and storeroom operations were integrated into the solution.

Results Realized: Plant maintenance was transformed into a well-planned operation utilizing a fully-integrated MRO storeroom to deliver improved master data, daily service levels and asset reliability performance.

Benchmark Goal Achieved
SOP Compliance 0% (no existing SOPs) 100% 100%
Zero Critical Spares Stockouts 70% 100% (meaning none) 100%
Stock Fill Rates 60% 98% 99%
Non-Stock Fill Rates 50% 95% 96%
Inventory Accuracy 65% 98% (through cycle counts) 98%
Inventory Reduction -7-10% (inventory was growing) 5-8% annually 5%

 

"A set of objectives and key performance indicators were established, the plant was benchmarked and storeroom operations were integrated into the solution."

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