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Client Quote
"The implementation of the Pragma Asset Management Programme at our Mobeni site provided us with a world-class tool that gives us the capability to effectively manage our assets to give us maximum OEE in an environment where we have a philosophy to 'sweat' our assets."
Eben Kloppers, Operations Director
Pragma Africa
Kwa Zulu Natal Regional Manager
Manufacturing & Mining
Laven Govender
Tel: + 27 31 266 8283
Fax: + 27 31 266 8257
Cell: +27 82 821 9655
laven.govender@pragmaworld.net
Client Background
Afripack is one of the largest independent packaging suppliers in South Africa and has successfully operated in the flexible-packaging markets for over 75 years. The Afripack philosophy has always been to invest in leading-edge first-world technology that can provide sustainable flexibility, as well as cost and speed advantages. To this end Afripack has invested R175 million in its plant and equipment over the past decade. The Afripack Industrial Flexible plant operates 24 hours a day, 7 days a week, with a realistic capacity of 140 million sacks per annum. Afripack is classified as a black-owned enterprise with a predominantly female shareholding. A level 4 BBBEE certification has been achieved.
Key challenges / Project background
- Maintenance costs and machine efficiencies.
- Asset Management Maturity.
- Using the information supplied by the Pragma ACC to move from a reactive to a proactive position.
The PRAGMA intervention
Afripack now have a structured approach to asset management by implementing the Tech-com and Steer-com Meetings as part of the Pragma Service. Through this the improvement actions can be driven by senior management as well as the technical staff. Listed below are the 10 Key Performance Areas (KPAs) that have been identified and will be focused on over the next year in order to elevate each one to a level 3 within the Asset Management Improvement Programme (AMIP) framework.
Strategy Management
- Develop an Asset Management Strategy
- Develop an Asset Management Policy
- Identify specific Key Performance Indicators (KPIs)
Information Management
- Use accurate information for proper planning
- Use business process flow to optimise data flow
Technical Information
- Formalise the sharing of information and knowledge
- Develop standards from technical information
- Formalise change control
Asset Care Plans
- Perform criticality analysis
- Revise the tactics selection
- Smooth out maintenance plan and link costs
Work Planning and Control
- Review all business processes
- Train staff on Work Planning and Control
Operator Asset Plans
- Expand operator responsibilities
Materials Manager
- Review slow-moving or obsolete stock
- Clean and tag
Support Facilities and Tools
- Initiate 5S Audit
Performance Measurements
- Align KPIs with the Asset Strategy
Focused Improvement
- Equip team leaders to be able to do Root Cause Analysis.
Business Processes and Best Practices
- AMIP Business Process
- Asset Register Administration
- Work Planning and Control.
Tools & Technology
On Key Enterprise Asset Management System with:
- Maintenance Manager
- Asset Care Plan Developer.
Performance Improvement
- Accurate asset data.
- Scheduled optimisation throughout the plant.
- Formalised work planning and control procedures.
- Asset Management Maturity levels have increased
- Autonomous maintenance has been formalised for two flexible lines.
The BOTTOM LINE
Equipment downtime can be analysed accurately using:- Components
- Failure Type
- Failure
- Repair Type
- Root Cause.
• Insurance Claim: Large claim honoured due to the fact that there was sufficient evidence that the equipment was being maintained.
