Industry Services
Integral Plant Maintenance
Maximum performance from your assets
www.siemens.com/ipm
Aligning asset management
strategies with business targets
iskey to improving profitability
International markets increase the need for productivity and efficiency
The continuing globalization trend opens up new markets for companies everywhere. This leads
tonew opportunities for both procurement and sales and, in turn, creates huge new potentials
forincreasing revenues and reducing costs. However, as economic boundaries disappear, global
players, smaller multinationals, and regional companies alike are faced not only with opportunities
but also with growing competition and relentless cost pressures.
These market mechanisms which cannot be directly influenced also have a major impact on
theprice of shares and costs of raw materials. In this market environment, a companys productivity
and efficiency play a key role in the achievement of their goals and this we can influence!
2
Asset management solutions
Asset performance improvement
Analysis and
Steps Awareness Implementation Sustainability
feasibility
Objective Improvement A concept is devel- Systematic realiza- Continual
potential is identified oped based on an tion of the defined improvement
in-depth analysis concept
Benefit Qualified foundation Comprehensive Improvement of Sustainable
for the next step implementation processes and andmanageable
decision concept supported achievement of the improvements
by a feasibility potential defined in
analysis (payback the previous phases
calculation)
Much more than just a cost factor Our solution: Asset management solutions for industry
Many companies still view maintenance as simply a cost Siemens Customer Services addresses the customers need
issue. Nevertheless, factors directly influenced by mainte- to access the potentials in this area through consulting
nance performance, including uptime, speed, and quality, services and long-term partnership, with a well-proven
have aconsiderable impact on profitability. Production approach that keeps companies profitable today and into
losses are hidden costs that need to be understood and the future.
controlled in order to ensure maximum performance from
Our step-by-step approach helps you align your asset
acompanys assets. Improving plant performance means
management strategies with your companys goals. At
achieving the right balance between maintenance
each stage in the improvement process, we provide you
resources and processes toensure optimized maintenance
with the facts you need to make your decision to move on
costs and the required production levels, which will at the
to the next phase. The result is a clear focus onthe right
same time maximize profits.
strategies for your company.
In addition to increased output and cost efficiency, best-
Implementing the prioritized measures, derived fromyour
in-class maintenance leads to a reduction in capital expen-
business targets delivers the following benefits:
ditures by extending the lifecycle of the equipment and
Improved performance of your assets,
optimizing stock levels of spare parts. In other words, it
increased production capacity, and higher
ispossible to benefit from producing more at lower costs
quality of the finished product
and over a longer period. This is the best way to avoid
Improved reliability of assets
further investment and to generate a higher return on
Improved efficiency of your maintenance
thecompanys capital.
processes with lower production costs per unit
Extended equipment lifecycle and
reduced investment requirements
Optimized spare-part stocks
Minimized health and safety risks
Integration of risk management
and contingency planning
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Improved processes
for better profitability
A solid foundation for best-in-class asset management
Identified potential:
Capital employed
Equipment uptime Cost efficiency and investments Safety and environment
ment processes
Asset manage-
Asset manage-
Asset manage-
and resources
management
Planning and
Organization
Performance
ment policy
Spare parts
scheduling
ment plan
control
Change management and continuous improvement
4
Asset management solutions
7.2 1.1 1.2
5
7.1 1.3
6.5 4 1.4
1.1 Management Commitment 5.4 Fault Management
andLeadership 6.1 Operational Analysis
6.4 1.5
1.2 Asset Management Policy 6.2 Maintenance Strategy & 3
1.3 Continuous Improvement Program PlanDevelopment
1.4 Risk Management/Contingency 6.3 Asset Life Cycle Cost Management 6.3 2.1
Plans 6.4 Plant and Equipment Condition 2
1.5 Quality Management Monitoring
2.1 Financial Control 6.5 Asset Management Plan 6.2 1 2.2
2.2 Plant Performance Control 7.1 Maintenance Planning
2.3 Asset Management Internal Audit andScheduling
2.4 Health & Safety Management 7.2 Major Overhauls 0
6.1 2.3
3.1 Organization Structure
3.2 Workforce Involvement
andEmpowerment
3.3 Personnel Development Program 5.4 2.4
3.4 Contractor Management
4.1 Spare Parts Management Processes
5.3 3.1
4.2 Warehouse Management
4.3 Workshops and Tools
5.1 Standard Procedures and Job 5.2 3.2
Instructions
5.2 Maintenance Management 5.1 3.3
Information System 4.4 4.1
5.3 Document Control System 4.3 4.2
Highest Average Lowest Current
We help you identify potential and achieve it!
We use a standardized assessment methodology step to By improving the maturity of your asset management
measure and benchmark the performance of your asset processes during the implementation phase, and ensuring
management processes. By identifying the gaps between continuous improvements with the right degree of man-
your actual performance and the improved state that agement attention in the sustainability phase, you are
canbe achieved in a given time frame, we estimate the ontrack to making asset management a success factor
improvement potential and the expected payback periods. inyour company.
Our benchmark database also provides you with powerful
Examples of improvement measures are:
insights into how other companies in your industry are
Alignment of the business strategy
performing. The experience weve acquired in projects
andthe asset management targets
allover theworld and across many industries confirms
Effective utilisation of maintenance
thevaluable improvement potentials in maintenance
management systems (CMMS)
costs and production performance that we can help you
Development of preventive and
to achieve.
predictive maintenance plans
Average values are: Training and coaching of maintenance
Cost reduction potential: 7.5 10 percent managers, planners, and reliability engineers
Improved equipment availability and therefore Implementation of a performance control system
overall equipment effectiveness (OEE): 2 4 percent based on key performance indicators (KPIs)
Warehouse optimization
5
Asset management solutions
A stepwise approach for improving the performance
of your companys physical assets.
Step 1 Step 2
Awareness Analysis and
feasibility
Paving the way to optimized In-depth review, risk analysis, and estimated
asset management investments and payback
The goal of this step is to give you The objective is to develop a comprehensive
aclear idea of the maturity and perfor- concept for the implementation. The main
mance levels of your processes before steps are:
you decide to proceed with an asset
Asset management review
management project.
An in-depth assessment that will investigate the
The standardized Health Check assess- improvement measures needed across all asset
ment is a two-day on-site analysis management processes and the interaction
performed by our most experienced between maintenance, production, and other
consultants. functions such as purchasing and finance. We
deliver a comprehensive report with all f indings
The results are:
and recommendations, a benchmark study on
Overview of the maturity of the
the maturity of your processes, and an accurate
asset management processes
calculation of the improvement potential.
Identification of the primary
strategies for driving improvement Alignment workshop
Rough estimation of the Once the improvement concept is clear, a
improvement potential workshop is held with your key employees to
Agreement on the next steps evaluate it along with the primary risks, and
thechallenges associated with implementing
themeasures.
The results are:
Detailed technical and financial
feasibility study
Estimation of the investment
and payback periods
Implementation roadmap
Overall risk management plan
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Asset management solutions
Step 3 Step 4
Implementation Sustainability
Realizing the improvement potentials Ensuring long-term continuous improvement
This step is based on our improvement program, To secure the true benefits of the investment
which provides you with a systematic approach to overtime, it is necessary to address the issue
implementing all of the recommended measures ofongoing improvement.
and realizing the identified potentials.
If, for example, maintenance management isnot
Typical activities during implementation are work- considered a core competence of your company,
shops to develop new procedures as well as assigning this task to a trusted p
artner could be
resource planning, training, and coaching of your your next step.
employees.
Within the scope of a performance-based con-
Our project management and professional sup- tract, this step can result in additional benefits
port ensure that you reach your targets by imple- aswell as bring about ongoing improvements.
menting the necessary improvements and guid-
In this case, Siemens can take care of your
ing you through this change management
assetmanagement processes and resources and
process.
actually manage and perform all maintenance
The results are: activities.
Professional and improved asset
It goes without saying that we apply the com
management processes
prehensive approach and tools explained in this
Organizational and behavioral
brochure to ensure best-in-class asset manage-
changes in the workforce
ment and continued improvement in all our
Implementation of new and improved
contracts!
strategies, procedures, and tools
Realization of the improvement The results of this agreement include:
potential, including: Improvement in maintenance performance
Equipment uptime and Long-term sustainability and
OEE improvement continuous improvement
Cost efficiency Contractual assurance of the agreed-upon KPI
Warehouse optimization Optimized spare-parts stock
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Our solution for long-term
continuous improvement
Long-term contracts are an important and strategic decision for your company. With our
proven experience, we can advise and support you to ensure that this is the right decision
forboth parties. The contractual model will be created to meet your specific requirements in
accordance with your specific business goals. Mutually derived key performance indicators
form the basis of this type of partnership. At Siemens we pride ourselves on jointly developing
and working in win-win partnerships with clear benefits for all involved.
8
Asset management solutions
Outsourcing
With Siemens as your partner for asset management
you can concentrate on your core business
A performance-based contract provides you with transparency,
control and additional financial benefits!
Siemens
Experience and know-how
Methods and tools
Asset management processes Contractors
Reliability engineering
Planning and scheduling
Customer
Outsourcing Offer provided on the basis of expected improvements,
Outsourcing with the Siemens IPM concept has only one state-of-the-art predictive maintenance techniques
goal, which is the very same goal that you have defined and equipment, experience from other contracts
for your business in general: to improve the efficiency and and proven implementation processes
effectiveness of the organization and reduce operational Negotiation and signing of contract
costs.
Close cooperation iskey to achieving the above-
This is independent of whether or not you see asset man-
mentioned goals.
agement as a core competence or prefer to concentrate
on the production process and allocate the responsibility The important objective in this case is to achieve a true
for asset management to an external partner. partnership as an essential basis for providing an inte-
grated and competitive solution. By working closely
In both cases, the experts from Siemens IPM will analyse
together with you, we increase the value forboth parties:
the actual status of your asset management as described
Best practices of all kinds and proven technical solutions
previously, in order to derive the improvement potential
are the basis for continuous improvement, sustainable
and show the path forward for change. The result:
OPEX reduction and increased uptime which areshared
Maintenance becomes a sustainably reliable partner
across our contracts.
forproduction.
For customers investing in a new site and production
If the decision is made to actually outsource the asset
facilities, on a green field, Siemens IPM ensures
management organization the contract will include
state-of-the-art asset management processes, tools
thefull improvement program to bring about the cost
andorganization right from the start.
reductions and increase uptime. The steps to OPEX
improvement are:
Analysis of the current status of the
maintenance organization (due diligence) and
evaluation of the condition of the assets
Evaluation of the potential for process
development, improved asset reliability, future
asset management organization as well as
spare parts and contractors management
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Asset management solutions
sustained optimization with
along-term partner
A successful approach to asset management combines the necessary one-time improvements
with implementing standard processes and tools that provide long-term gains. Inherent to all
improvement projects is the people factor: This means change management, and requires
the attention of top management. The risk that old practices and habits will return and
efficiency will fall off again needs to be addressed. Siemens has both the experience to com-
petently address these concerns and the willingness to enter into long-term partnerships so
that improvements are sustained.
10
Asset management solutions
In the spirit of beginning with the end in mind, we take By increasing your asset utilization and cost efficiency in
all of your long-term considerations into account as we combination with our energy and environmental services,
work closely with you through the phases described in we can support you in increasing your energy efficiency
thisbrochure. and reducing your overall CO2 emissions as well.
Here is a summary of the benefits that we can offer:
Lets work together to make asset management
Improved overall utilization of your physical assets
oneofyour companys competitive advantages!
to increase the uptime of your production plant
and therefore your marketable production output
Asset management from a cost factor to a value
Implementation of new and improved asset
adding successfactor!
management processes to optimize and achieve
higher utilization of human resources. This
increases your overall cost efficiency
Improved quality of the maintenance activities to
ensure better reliability and longer useful life of your
equipment. This reduces your overall investment
Reduction of spare-parts stock, the total cost for
spare parts, and increased stock reliability by
addressing the maintenance issues of critical parts
Risk mitigation and sound decisions at each
stage of the overall improvement process
Continuous improvement integrated
into daily work routines
Increased motivation and competence
of the maintenance staff
Better maintenance cost control and
reporting, increased transparency, and
improved budgeting and forecasting
Better maintenance planning, improved production
planning, and improved supply chain processes which
are connected to the asset management processes
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Published by and copyright 2012:
Siemens AG
Industry Sector
Customer Services Division
Value Services
Werner-von-Siemens-Str. 65
91058 Erlangen
Germany
E-mail: IPM.industry@siemens.com
Order No.: E10001-T430-A235-V2-7600
Printed in Germany
Dispo No.: 21639 | K No.: 38300
TH 241-120791 | WS | 08120.5
Subject to change without prior notice
Printed on elementary chlorine-free bleached paper. Subject to change without prior notice.
The information in this document contains general
All rights reserved.
descriptions of the technical options available, which
Trademarks mentioned in this document
may not apply in all cases. The required technical
are the property of Siemens AG, its affiliates,
options should therefore be specified in the contract.
or their respective owners.
