Case Study – Chemical Plant UpliftmentGlobal Explosives Manufacturer VIC, Australia
Our client, a global manufacturer of explosives for mining and quarrying, faced a challenge at their Emulsifier plant. This site had problems with its asset data and equipment performance compared to their other plants. With rising global demand, they needed to increase output and improve reliability. This case study explores how, with the help of EnterpriseIS, they improved their asset management, making their operations more resilient and successful.
The Challenge
Our client operates several manufacturing plants globally to produce a range of explosives for mining and quarrying.
Our client identified that this site has gaps in asset master data and lags other sites in terms of asset management maturity and equipment uptime.
To meet with growing global demand the need existed to increase output, and improve both reliability, and availability of their Emulsifier plant.
The Solution
To achieve reliable and sustainable operations requires a robust approach to asset management, and in this case the first step was to review the accuracy of the existing master data.
EnterpriseIS carried out a thorough survey of the entire plant and process to collect asset data for comparison against process drawings and functional location records to identify gaps.
The next step was to build an accurate asset register and conduct a criticality analysis to determine which assets posed the greatest operational risk should they fail to perform. A comprehensive critical spares analysis followed to determine spares inventory in preparation for cataloguing.
Using the outputs from the criticality analysis, failure modes, maintenance history, and OEM recommendations, EnterpriseIS were able to build a comprehensive maintenance strategy and a suite of targeted work instructions to incorporate in job packs.
The Results
EnterpriseIS were able to achieve the following for the client;
- Identified 90 assets without functional locations
- Located 35 discrepancies between actual plant & P&ID’s
- Assessed over 1800 individual assets
- Developed over 500 work instructions & checksheets
- Developed over 1800 targeted maintenance strategies
- Curated a list of critical spares for cataloguing.