Looking at the bigger picture

Effective maintenance comes not only through establishing a regular,practical routine but by periodically taking a step back and evaluating the different ways in which it can be provided. Nigel Ord, general manager of fluid power at ERIKS, outlines the benefits a specialised partner can bring

Asuccessful engineering operation needs to establish a strong, methodical approach to the regular maintenance of machinery in order to maximise productivity and efficiency.

However, there is always more than one way to tackle any given problem and it pays to reevaluate your processes from time to time.

For example, is it more efficient to manage maintenance using your own staff, or to use outside help and potentially reap greater rewards by capitalising on your partner's added knowledge and experience? Certainly, if you are considering using outside help from a supply partner, it is important to make sure that you are getting a good deal, and that means enlisting the help of an organisation with the expertise, experience and capability to add value to your business by suggesting ways to refine your systems and make real cost savings.

For example, ERIKS has identified a series of significant savings for a major automotive manufacturer in 2012. A comprehensive programme has been put together to encompass a number of initiatives, from condition monitoring and analysis activities that form part of the preventative maintenance schedule, to the provision of improvements and upgrades to equipment included in our range of savings projects.

The total savings value of our optimisation programme is estimated at £250,000.

That kind of saving makes fast payback on the cost of using a partner and soon starts pumping the savings back into the business. The best way to achieve this kind of benefit is to ensure that your partner offers a depth of expertise in your specific industry and range of experience in others. It is also important that your partner offers both a variety of high quality supplies and a strong repair and maintenance service; a partner with limited capabilities may be tempted to suggest solutions that benefit their own limited parts and service offering but a more experienced organisation with a broad range of products will have no need of this and, instead, simply select the solution that is best for you.

A good partner can make positive changes fast; high-risk, performance-critical areas will be analysed first and changes in the repair and maintenance regime implemented.

Once short and medium term issues have been addressed, your partner can then investigate and evaluate your entire system as part of an on-going process to identify new opportunities for savings and improvements.

Case study Big savings can be made right from the start of the partnership, as ERIKS proved when it came to the aid of a well-established company in the food and beverage sector.

On this occasion, we identified a problem of which the company was not previously aware: a series of air leaks in compressed air systems. Using ultrasonic technology, the leaks were detected in just two days, with no disruption to production. Our survey data was compiled and presented in detail, with an actual financial loss related to each leak.

By acting on our data and implementing our suggested remedies, the company achieved savings of £86,000 a year.

This particular case study illustrates an important point when considering whether to opt for assistance with MRO: the factory's compressed air installation was by no means poorly maintained or specified, it was regularly maintained and in reasonable condition.

Nevertheless, the use of ultrasonic technology by expert engineers trained in its use revealed a whole series of potential savings.