- Assessment of the status quo of maintenance excellence and the level of digital maturity in maintenance.
- Identification of areas for improvement, pain points and evaluation of potentials.
- Definition of optimization measures and design of an implementation roadmap.
INCREASE OEE AND REDUCE MAINTENANCE COSTS
MAINTENANCE EXCELLENCE
Maintenance Excellence makes a significant contribution to reducing costs or preventing them in the first place. This improves the efficiency and effectiveness of maintenance processes and increases plant availability. Fruitful starting points for improvements are, for example, the use of mobile maintenance technologies, predictive maintenance and targeted employee training.
Overall, maintenance excellence results in a longer machine service life, lower operating costs and higher productivity - and thus strengthens companies in terms of profitability and competitiveness.
Take advantage of ROI-EFESO's expertise to achieve excellent availability and OEE (Overall Equipment Effectiveness) of your machines and systems at low maintenance costs. Realize systematically potential savings and further opportunities for improvement in maintenance - depending on your needs, we will focus on these areas:
Results
Companies achieved these improvements with ROI-EFESO in maintenance excellence projects:
Project "Maintenance Boost": Compensation for significant deviations in maintenance costs and OEE values that existed between individual plants of the company despite identical products and production processes.
Approach:
- Transparency / comparability of maintenance processes established in each plant.
- Cost and performance-critical elements identified and immediate measures defined.
- Group-wide maintenance system and plant-specific development plans created.
Results:
- Response times significantly reduced.
- Maintenance processes made much more efficient.
- OEE values significantly improved.
- Overall maintenance costs greatly reduced.
OPTIMAL MAINTENANCE PROCESSES WITH ROI-EFESO
Increase the maturity level of machine and plant maintenance. We ensure results in four steps.
1. Maintenance Excellence Analyse
2. Planning and initiation
- Creating the foundations for the transformation of maintenance with the responsible employees in the company.
- Initiating implementation in pilot projects.
3. Implementation and rollout
- Completion of the initiation of pilot projects.
- Enabling the maintenance team in the company to roll out the measures throughout the organization.
MORE SERVICES
Cost Reduction Approach
Cost down - Perfomance up!
Zero-Based Organization
Next Gen OPEX
CapEx Optimization
Value & Cost Engineering
Digitalization Excellence
Inventory Excellence
CASE STUDIES - PRACTICAL EXAMPLES
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Cost reduction/restructuring due to market changes
A plant and mechanical engineering company had to ensure its competitiveness. ROI-EFESO identified all the adjustment screws for the necessary changes at a production site in Germany and got the turnaround going with a multi-layered restructuring approach.
Zero-Based Organization
Champions do not rest contentedly with their success, but always have their sights set on the next milestone. A technology group with around 20,000 employees at over 16 locations worldwide is also orienting itself in the direction of such a “North Star”. His starting points: an operational strategy and the initiatives derived from it, which should be implemented at every location in order to make them even more efficient.
Value and Cost Engineering
Cost transformation from premium to volume provider. Mass manufacturers who expand their Product portfolio into higher price segments are not uncommon. A premium manufacturer of refrigeration appliances, on the other hand, takes the opposite approach. What seems banal from a technological point of view is an enormous challenge from a cost perspective. ROI-EFESO accompanied the company in this demanding transformation project.
Streamline production and logistics
The Italian group Marcolin S.p.A. has been designing, manufacturing and selling sunglasses and optical lenses for well-known brands such as Tom Ford, Bally, Moncler, Sportmax and Ermenegildo Zegna for 60 years. In 2018, she sold more than 14 million pairs of glasses through 150 distributors in 125 countries. Optimal management of the fashion company's international supply chains and production processes is correspondingly important.
Safeguarding the site thanks to lean value streams
With hard targets for the entire operations area, a valve manufacturer is aligning a plant location for the future - and thus securing the site in Germany. Together with ROI-EFESO, the company restructures its manufacturing and logistics and achieves, among other things, an OEE of more than 85%.
Cushioning cost pressure with energy management
A dairy group identifies the topic of energy efficiency as a lever to cushion cost pressure from falling production volumes. The case study explains, how the company determines with ROI-EFESO suitable starting points for one of its plants. The potential of the measures in terms of possible energy savings, their CapEx and their amortization are specifically quantified.