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Client Quote
"The establishment of the ACC offices with personnel using and applying the Pragma AMiP is now starting to show results and benefits. We anticipate and expect further significant benefits as the process unfolds and develops into the future."
Mr B Sutherland, Aberdare Project Leader
PRAGMA AFRICA
Divisional Manager
Manufacturing & Mining
Ronnie Taljaard
Tel: +27 21 943 3900
Fax: +27 21 948 9945
Cell: +27 82 565 6054
ronniet@pragma.co.za
Client Background
Aberdare Cables, a member of the Powertech Group, is a leading global manufacturer of cables with five manufacturing sites, in three provinces of South Africa, and offshore operations in Mozambique, Portugal and Spain. The company’s customer base includes government utilities, municipalities, as well as industries such as petrochemical, mining, wholesale, industrial, construction and domestic building. The company manufactures and sells a wide range of state of the art products. Aberdare Cables prides its self on its ability to identify and satisfy customer needs through development of innovative products; unique, cost effective cable solutions for a wide range of industries.
Key challenges / Project background
- Implement sound asset care strategies within a cable manufacturing environment.
- Ensure process stability though sound maintenance policies and procedures.
- Improve the maintenance spares system in line with sound management practices.
- Enable control over maintenance costs and then optimise cost efficiencies within the business.
The PRAGMA intervention
Aberdare established the contract with Pragma’s Asset Care Centre (ACC) Service in 2007. The partnership entailed setting up ACC Service offices at the 4 manufacturing sites (Long Street, Eloff Street, Pieter Maritzburg and Port Elizabeth), to introduce standardized physical asset management practices across the company. The SAP R/3 Plant Maintenance module was implemented in support of the Pragma business processes to ensure effective implementation.
The Long Street operation was used as pilot site, with established procedures and methodologies being rolled out to the other sites. All the sites are now fully operational, with the ACC Service employing 9 people (manager, planners and administrative support) at the 4 sites.
Business Processes
The following business processes are implemented through the ACC Service:
- Asset Care Foundations, to develop and set asset management policy, strategy and standards.
- Asset Management Improvement, to ensure ongoing optimisation of practices.
- Asset Register Administration, to build and maintain a comprehensive asset register.
- Work Planning and Control, to manage the life cycle of asset related work (tactical and non-tactical).
- Maintenance Program Development.
Tools & Technology
- Asset Management Improvement Process (AMIP)
- SAP R/3 Plant Maintenance Module
Performance Improvement
- Optimisation of the SAP R/3 Plant Maintenance module as CMMS.
- Standardised work planning & control procedures across all sites.
- Introduction of improved reporting to manage maintenance.
- Stabilisation of all sites in respect of physical asset care activities.
The BOTTOM LINE
- More visibility in respect to failures.
- Reduction in breakdowns.
- Increase in effective preventative maintenance.
- Control and eventual reduction in costs.
- Control & optimisation of spares.
Quote from the client
"We use Pragma as an impartial company to implement best maintenance practices through out all our factories, therefore also ensuring standardization." Deon Smulders - Engineering Manager
