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Client Quote
"We used to think we conducted regular plant maintenance, but through the use of the Pragma service and the performance measurement system our perspective has broadened to the practice of plant asset care"
Lofty Eksteen - Maintenance Manager: Ceres Fruit Juices
Pragma Africa
Regional Manager
Manufacturing
Ronnie Taljaard
Tel: +27 21 943 3900
Fax: +27 21 914 7337
Cell: +27 82 565 6054
Ronnie.taljaard@pragmaworld.net
Client Background
Ceres Fruit Juices is South Africa's leading fruit juice company and major exporter of well-known brands such as Ceres, Liqui Fruit and Fruitree. Currently Ceres exports to more than 84 countries in Africa, Europe, the Far East, the Middle East, Asia and North America. Through careful planning, potential new markets are constantly evaluated for long-term sustainable growth and commercial viability.
Ceres Fruit Juices is a consumer-orientated business, operating at world-class standards, with complete dedication to unique products and their brands. Ceres is serious about continuous improvement, and constantly strives for operational excellence. This commitment to quality, ongoing product innovation and leading-edge marketing explains why they are the South African long-life fruit juice category market leader with a market share in excess of 50%.
Key challenges / Project background
Ceres is rapidly expanding their markets, and as such their production capacity is constantly under pressure. To deal with this they require maximum uptime and equipment reliability. As a major exporter, Ceres is exposed to currency fluctuations. The best way to deal with this is to reduce risk through operational excellence. This means eliminating breakdowns, wastage and slow running. Ceres demands extreme operational efficiency, implying world-class asset availability and production rate levels.
The PRAGMA intervention
Ceres predominantly uses Tetrapak equipment, so plant - maintenance scheduling was conducted according to Tetrapak guidelines. Ceres required a system able to adjust maintenance scheduling and servicing of machines according to their specific requirements, and set new targets accordingly.
Ceres started using the ACC@Pragma service. Pragma receives job cards weekly, captures the information and produces monthly reports based on the data gathered. Metrics such as artisan utilisation and schedule attainment are analysed. Trend mapping highlights repetitive problems across all machines in the plant. In this way preventative maintenance schedules are adjusted to prevent recurrence of the problems, performance standards are set and continuous improvement is achieved across the production lines. Ceres also implemented the Performance Measurement module of On Key, providing real-time, online monitoring.
Busine Processes & Best Practices
The following key business processes were implemented:- 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).
- Asset Management Improvement, to ensure ongoing optimisation of practices
Tools & Technology
- On Key - Pragma's enterprise asset management system, connected to the Pragma office in Cape Town
- Weekly and monthly reporting.
Performance Improvement
- Increased asset productivity
- Reduced asset-related risk
- Improved data velocity
- Spares maintenance included in PM programme
- Increased tactical work.
The BOTTOM LINE
- PM schedule attainment > 85%
- Breakdowns < 10 per month
- 19% improvement (Q1 2010 - Q1 2011) against KPI matrix
- Successful implementation of over inspection.
