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Client Quote
"A definite proactive and excellent management tool in helping to make the right strategic decisions adding a lot of value to our company's assets and financial structure."
Tonie Grobler, Group Engineer
"At our Bloemfontein site, downtime plunged from 92 hours (October '10) to a mere 10 hours (March '11) per month. Production stats are directly proportional to this figure and increase in tons made per month on this site"
Maintenance Planner
"I think it was a very successful implementation from both sides. We are past the fire-fighting stage and looking forward to implementing the Materials Manager Module"
Jan Smal, Maintenance Manager
Pragma Africa
Northern Regional Manager
Manufacturing & Mining
Johannes Coetzee
Cell: +27 82 44 77 999
Tel: + 27 11 318 0641
Fax: + 27 11 316 0666
Johannes.coetzee@pragmaworld.net
Client Background
NUTRI Feeds is the leader in animal feed manufacture in South Africa, and a global player in the animal feed industry. With their head office in Potchefstroom and manufacturing plants in Viljoenskroon, Mafikeng and Bloemfontein, NUTRI Feeds is the countrywide first choice in animal feeds for pigs, sheep, poultry, dairy and beef cattle. NUTRI Feeds products are not only freely available in South Africa, but also in Lesotho, Botswana and Namibia. Their mission is to "manufacture, distribute and support superior animal feed to enable our customers to be the lowest-cost producers of animal protein".
Key challenges / Project background
- To make a complete paradigm shift regarding the methodology of operations, personnel training and implementation of electronic maintenance work orders.
- To continuously drive the project with the required energy, vision and leadership from the top to be able to successfully realise the required project goals and outcome.
- To create accurate flow diagrams and corresponding MSIs (maintenance significant items) for all plants (this was a great success in the time frame planned).
- To minimise breakdown hours with the help of scheduled maintenance on all assets in their feed mill plants, and to cut costs related to breakdown times and artisan utilisation.
The PRAGMA intervention
NUTRI Feeds had an absolute history of breakdown maintenance and virtually no scheduled maintenance resulting in poor performance, efficiency and high replacement costs. Therefore it was imperative to implement a complete electronic maintenance cycle starting with asset management in all plants. They chose Pragma as their physical asset management partner and the implementation of the On Key EAMS commenced early 2010 at their Viljoenskroon Mill, thereafter rolling out to the Mafikeng and Bloemfontein plants. The project was successfully signed off in January 2011 and the NUTRI Feeds in-house asset care resources (maintenance planners and data capturers) are completely enabled to operate the Pragma On Key EAMS tool.
Business Processes & Best Practices
Together with NUTRI Feeds, Pragma developed an asset management strategy standard for maintenance planning throughout the whole NUTRI Feeds Group. Pragma Africa developed all asset management-related business processes for Nutri Feeds to follow.Tools & Technology
The following On Key Enterprise Asset Management Modules were implemented:
- Asset Management Module, to build and maintain a comprehensive asset register.
- Maintenance Manager Module, to manage the life cycle of asset-related work (tactical and non-tactical).
Performance Improvement
- Significant improvement in downtime, costs and efficiency in all plants.
- Artisan utilisation and efficiency has improved.
- Above average buy-in from staff and users into maintaining the system.
The BOTTOM LINE
- Reduction in breakdowns leading to higher production output.
- Increase in effective preventative maintenance.
- Total buy-in from resources to practise the standardised asset care function.
