Maintenance Excellence Program

An international manufacturer of complex plants for the energy industry was confronted with maintenance costs and OEE values which, despite identical production processes and products, differed significantly between the individual plants. Therefore, clarity about the different performance levels should be created and standards for organization, processes and instruments should be defined and adapted in the global plant network. The company wanted to combine short-term optimization initiatives with a medium-term change program.

The ROI Maintenance Excellence Toolset ensured comprehensive transparency and comparability of the maintenance processes in each plant. The results were analysed using target values as well as internal and external best practices. On this basis, critical elements were identified and a catalogue of immediate measures was defined. On the other hand, the company worked with ROI to design a detailed group-wide maintenance system and derived plant-specific development plans. As a result, the project succeeded in significantly shortening response times, making maintenance processes much more efficient, significantly improving OEE values and significantly reducing overall maintenance costs.