Successful companies understand the value of reliable equipment and invest time and resources in protecting their manufacturing assets. When equipment falls short of its full potential, uptime, quality and efficiency suffer. Ultimately, unreliable equipment impacts financial performance, as the business incurs the costs of parts and labor for repairs, the process loss due to scrap and low-quality product, and lost profit opportunity.
The Challenge of Maintaining Production Assets
MAVERICK Technologies can develop customized reliability systems or complement your current reliability programs. MAVERICK's operational consultants and engineers have developed a time-tested and highly successful approach to improving equipment reliability. With a focus on the design, implementation and integration of asset lifecycle management solutions, our services include:
- Maintenance and reliability program assessment
- Customized maintenance and reliability program development
- Preventive maintenance job task library creation
- Computerized maintenance management systems (CMMS) selection, configuration, data migration and implementation
- Breakdown elimination workshops and coaching
Maintenance and Reliability Program Assessment
MAVERICK offers objective benchmarking for plant maintenance management programs, performing in-depth analysis in the following areas:
- Work order system
- Planning
- Scheduling
- Preventive maintenance
- Emergency and safety work management
- Work execution
- Budgets
- Training program
- Procurement practices
- Maintenance, repair and operations (MRO) inventory function
Beyond providing an extensive report of findings and an executive review, MAVERICK can recommend paths forward and can work with plant personnel to assign priorities. Benefits include unbiased expert analysis of maintenance management and reliability improvement opportunities, and a low-cost first step in the journey toward operational excellence through reliable equipment.
Customized Maintenance and Reliability Program Development
At MAVERICK, we believe that every endeavor to improve maintenance and reliability should have lasting benefits. MAVERICK develops custom strategies for building methodical and foundational maintenance and reliability programs that yield enduring improvements.
MAVERICK helps clients create strategies, plan function block activities and maintain a program timeline. Click to enlarge.
Preventive Maintenance Job Task Library Creation
High-quality preventive maintenance task lists are key to world-class maintenance programs. They standardize best practices and establish long-term work standards. Job plans should be clearly written so that any person possessing the requisite training can successfully complete the required tasks. MAVERICK helps clients build best-practice PM job cards that lay the foundation for successful and sustainable maintenance and reliability programs.
Computerized Maintenance Management Systems (CMMS) Selection, Configuration, Data Migration and Implementation
The heart of a robust maintenance and reliability program is its CMMS program, accompanied by sound business processes. Most CMMS programs provide solutions in the following areas:
- Work order management
- Work planning and scheduling
- Asset management
- Equipment and work history
- Preventive maintenance
- Material management
- Bill of material
- Key performance indicators
- Budget analysis
- External service orders
Choosing the right solution is an important step in the journey to high asset reliability and availability. MAVERICK's vendor independence ensures that we help you choose the solution that solves your specific challenges. We have expertise in a number of CMMS software applications, including those from the following providers:
- SAP plant maintenance (PM) and materials management (MM) (visit site)
MAVERICK has the SAP expertise needed to:
- Implement all logistics modules
- Configure and customize SAP to clients' specifications
- Perform equipment and material master data migration and cleanup
- Create and clean bill of materials
- Provide complete MM and PM workflow processes
- Create preventive maintenance tasks and a load-balanced schedule
- Supply hands-on SAP training
- Provide go-live support
- Offer extended post-startup support
- IBM Maximo (visit site)
- eRPortal (visit site)
- Mtelligence (visit site)
Breakdown Elimination Workshop and Coaching
MAVERICK offers a hands-on Breakdown Elimination workshop for supervisors, technicians and operators. This workshop leads participants through our nine-phase Breakdown Elimination Program designed to target and reduce equipment and component failures. Attendees will learn how to:
- Organize a team
- Gather information
- Perform cost analysis
- Discover irregularities
- Perform a root cause analysis
- Evaluate and implement countermeasures
- Make systemic improvements
- Verify improvement results
- Reapply improvements to similar equipment / components
Attendees will receive a step-by-step guide to our methodical approach that yields repeatable results. By participating in our workshop, your business will encourage greater employee involvement in problem solving while freeing up your engineering staff to focus on other work.