Multi-site CMMS adoption across Kingspan Group

ADVANCED INSULATION and building envelope solutions manufacturer Kingspan faced challenges in managing its maintenance activities and tracking asset performance. The company needed a comprehensive Computerised Maintenance Management System (CMMS) that could be rolled out to a large workforce across multiple plants globally.

PEMAC worked closely with Kingspan to implement its best-in-class PEMAC ASSETS CMMS software and provide training to ensure the software was utilised effectively. PEMAC delivered the following solution to Kingspan:

Work order management and preventative maintenance

• Enabling reduced downtime by capturing more details for analysis, and improving decision-making around maintenance resourcing.
• Automated transfer of detailed work instructions across sites globally.
• Capturing complete historical records of all interactions per machine assisting Kingspan with audits.
• Improved CMMS usability through the PEMAC mobile app increasing the accuracy and timeliness around job closeouts

Inventory management

• A common view of spares shared across all sites, reducing downtime and minimising the amount of capital tied up in parts.
• Improved spare parts management and rationalisation.

Asset performance and reporting

• Delivering reports as required by Kingspan’s Corporate Key Performance Objectives.
• Improved understanding of resourcing and training needs.
• Ability to export routine and work order data into MS Excel.
• Supporting Kingspan’s requirements for ISO Certification.

Systems integration

• The ability to integrate ERP with CMMS provides Kingspan finance with greater visibility over maintenance costs and cost control.
• Purchasing is managed directly within CMMS rather than ERP.

Benefits

Improved efficiencies

The sharing of work order instructions across global sites has standardised Kingspan’s maintenance practices and consistency of work. This has facilitated improved efficiencies via group-wide benchmarking and the sharing of lessons learned and maintenance best practices.

Cost reduction

Spare parts rationalisation and visibility across regional business units allow individual Kingspan sites to share parts with each other as and when required. This reduces the need to carry large quantities of inventory at each site, reducing the overall inventory-carrying costs for the group.

Improved downtime analysis

PEMAC ASSETS has vastly improved Kingspan’s ability to analyse and report on its equipment downtime. With more detailed downtime information available via CMMS, Kingspan can perform detailed analysis to correctly identify how to reduce downtime, resulting in significant cost savings and increased profitability.

Health ad safety compliance

PEMAC ASSETS gives users within Kingspan full visibility of production equipment and machinery, as well as workplace safety equipment, such as PPE and eye wash stations. Ensuring equipment is always in perfect working condition protects Kingspan employees and reduces associated insurance costs.

Summary

PEMAC has a longstanding relationship with Kingspan, with its software now used in more than 20 Kingspan plants across the US, Europe, Asia, and Australia. Since implementing PEMAC ASSETS CMMS, Kingspan has significantly improved maintenance efficiency, reduced downtime, and increased productivity.

"PEMAC ASSETS CMMS allows us to track asset performance in real-time, schedule preventative maintenance, and monitor inventory levels, among other benefits. The software has also helped Kingspan save time and money by streamlining our maintenance processes," said Ken Graham, divisional planned maintenance leader at Kingspan Insulation.

For more information:

www.pemac.com

Tel: +44 161 710 3346