First of all, reaching this state for your organization will take a significant amount of time, money, discipline and effort. It will be a journey that needs clear goals and 100% buy in from every stakeholder, manager and employees in order to succeed. It is not possible to buy fancy bits, pieces and software and achieve a true Maintenance 4.0 state. We center our advisory and project scoping around the following 3 elements and alignment within Asset Management:
Systems:
- Only systems that is creating value must be used, and as few as possible. Keep the governing ERP system the true governing system of everything possible
- Have the system designed for your business, not the other way around
- Focus on the definition and governance for good data quality
- Have the basics in place; calendar and performance based maintenance, classification data and an as-built representation of your assets
- Compliance and safety measures transparent – license to operate
Processes:
- Management of Change, as-built updates
- Have the 3C’s in place for your master data: Create – Change – Control
- Failure reporting
- Root Cause Analysis
- Priority and planning
- Roles, responsibility and competency management
Employees:
- Clear understanding of purpose and value for the business
- System and process understanding and training
- Data understanding
- Advanced maintenance theory education for key personnel
- Enforce a reliability culture, similar to safety culture in most organization, especially within oil & gas
Depending on the size of your organization the above headlines will be journey of 2-4 years. By then it will be possible to fully implement cloud server solutions and install the needed sensors and software solution to assist you in the final steps with condition based and predictive maintenance and towards a Maintenance 4.0 environment.
