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The first task to achieve ‘No unplanned failures’ was to develop a strategic vision for reliability at the plant. Secondly, to develop an implementation plan. Lastly, to develop a reliability Best Practice document for their manufacturing group. The ultimate aims of this process would be to accelerate reliability-centred plant initiatives, mitigate risk exposure to critical spares gaps, increase productivity, obtain an insight into the assets’ status, and enable smarter replacement thanks to optimised monitoring.

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Often when equipment fails, the biggest concern is how to get it running again. However, equally as important is finding the root cause and how it can be avoided in the future. By providing managers and service technicians with the knowledge to identify causes of gearbox failures, they can establish an effective preventative maintenance program to support their plant and site operations.

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If half the motors that fail on your site every month have the same failure mode, you might think it needs a magic wand or a miracle to solve the problem. But for a customer operating the largest tinned soups and beans manufacturing facility in Europe, all it took was some ERIKS know-how to reduce that figure from 50% to 6%. 

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Profiting from the expertise of many internationally-renowned universities and research laboratories, pharmaceuticals manufacturing accounts for nearly ten per cent of all manufacturing in the UK, with exports worth up to £30 billion a year.

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Just managing is reacting to problems. Asset Management is anticipating them. Just managing is allowing assets to lose efficiency. Asset Management is maintaining them at their optimum. Just managing is tolerating downtime. Asset Management is improving uptime. Asset Management is not hard. In fact, any business can manage to do it. 

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Industry’s productivity, profitability and reputation depend on the correct functioning of its equipment. But, when equipment fails, is a quick fix or a detailed investigation the best course of action, and what role can Total Cost of Ownership calculations play in the final decision? 

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To repair, or to replace? That is the question. At least, it is for manufacturers, who are coming under increasing pressure to do more with less, while squeezing out the last drop of potential from every available resource. Enter Total Cost of Ownership (TCO), the acronym that’s here to help, but only if you do it right.

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