Confectionary Manufacturer, 2008/09
With 5 production sites, 4000 employees and market share in 50 countries the business wanted to improve and standardise maintenance processes across its facilities. Following an analysis it was identified that the business was hampered by historically-constrained organisation structures, a low ratio of planned to unplanned work as well as an unsatisfactory work-order system. In addition, significant OEE improvements were also identified. Project implementation included the creation of a single and unified Enterprise Resource Planning (ERP) solution, to satisfy all commercial and technical requirements, simplify planning & scheduling and ensure sustainability. The next aspect was to determine the optimum maintenance structure and adapt the roles and responsibilities so tasks and requirements could be standardised. The following benefits were realised:
Reduction of maintenance budget by 17%
50% reduction in breakdown related costs
Increase in the planned ratio of work from 20% to 60%
Overall savings range from €3.5m to €4.5m p.a. per site.