Improving Asset Performance for a Global Manufacturer

Manufacturers rely on efficient asset management to reduce downtime, control costs, and maintain production efficiency. A global manufacturer faced frequent unplanned maintenance, rising operational expenses, and inefficient asset utilization, affecting productivity. By implementing IBM Maximo’s Reliability-Centered Maintenance (RCM) strategies, the company reduced unplanned maintenance by 40% and achieved annual savings of $500,000.

Challenges

• Frequent equipment failures, causing production delays and increased downtime.

• High maintenance costs due to reactive maintenance approaches.

• Lack of asset performance insights, leading to inefficient planning.

• Difficulty in prioritizing maintenance tasks, impacting overall productivity.

Solution: Implementing IBM Maximo for Reliability-Centered Maintenance (RCM)

The manufacturer integrated IBM Maximo’s RCM strategies to shift from reactive to proactive and predictive maintenance, optimizing asset performance. Key features utilized:

• Failure Mode and Effects Analysis (FMEA): Identified potential failure risks and implemented preventive measures.

• AI-Driven Predictive Maintenance: Used data analytics to detect equipment issues before failure.

• Automated Work Order Management: Prioritized critical maintenance tasks for efficiency.

• Condition-Based Monitoring: Tracked asset health in real time for proactive decision-making.

Results & Benefits

• 40% reduction in unplanned maintenance, improving overall equipment reliability.

• $500,000 annual cost savings through optimized maintenance scheduling and reduced downtime.

• Extended asset lifespan, minimizing capital expenditures on new equipment.

• Increased production efficiency, reducing delays and improving output.

Industry Statistics Supporting the Need for RCM

• Unplanned maintenance can cost manufacturers 10x more than planned maintenance. (Source: McKinsey & Company)

• Reliability-Centered Maintenance can increase asset uptime by up to 50%. (Source: Deloitte)

  
  

Conclusion

By leveraging IBM Maximo’s RCM strategies, this global manufacturer transformed its asset management approach, significantly reducing costs and improving reliability. With predictive analytics and proactive maintenance, manufacturers can achieve higher efficiency, reduced downtime, and long-term cost savings.

Want to optimize your asset performance? Contact CMEx today.