simain business based maintenance · many companies still see maintenance only as a cost factor....

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SIMAINBusiness Based MaintenanceMaximum performance from your assets

Industrial Technologies


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Aligning maintenance strategy with business targetsis key to generating value for your company

International markets increase the need forproductivity and efficiencyGlobalization is opening up new markets for companieseverywhere as well as expanding their opportunities forboth procurement and sales. These opportunities createhuge potential for revenue growth and cost reductions.However, as economic boundaries disappear, globalplayers, smaller multinationals and regional companiesalike are faced not only with opportunities but alsogrowing competition and relentless cost pressures.

These market mechanisms, which cannot be directlyinfluenced, also have a major impact on share prices andthe price of raw materials. In this market environment,productivity and efficiency play a key part in achievingthe strategic goals set by your company.

Much more than just a cost factorMany companies still see maintenance only as a costfactor. Nevertheless factors directly influenced bymaintenance performance such as uptime, speed andquality have a considerable impact on financial results.Production losses are “hidden” costs that need to beunderstood and controlled in order to extract maximumperformance from a company's assets.Improving maintenance performance means achievingthe right balance between maintenance resources andprocesses to ensure optimum maintenance costs andproduction levels according to the company's targets and,at the same time, maximizing profit levels.

In addition to production increase and cost efficiency,the achievement of a high level of maintenanceperformance means reducing the capital employed bythe company by increasing the lifecycle of the equipmentand optimizing spare parts stocks.In other words you can benefit from producing more,with lower costs and for a longer period. This is the bestway to avoid new investment needs while at the bottomline generating a higher return on the company’s capitalemployed.


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Phases Awareness

Maintenance ImprovementIntegral Plant

Maintenance

Analysis and Feasibility Sustainability

Demand

Benefit

Identification of

improvement

potential

Competent

support for

a confident

go / no-go decision

Development of a

concept based on an

in-depth analysis

Comprehensive

implementation

concept supported by

a feasibility analysis

(ROI calculation)

Systematic

implementation of

the defined concept

Improvement of the

processes and

achievement of the

potential defined in

the previous phases

Management

attention focused

on maintenance

processes (Continuous

Improvement Process

(CIP))

Sustainable and

manageable

improvements

Implementation

Business Based

Maintenance

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Our solution: SIMAIN Business BasedMaintenanceSiemens Industrial Technologies – the technical servicesprovider of Siemens for industry and infrastructure –has developed the SIMAIN® Business Based Maintenancesolution within our Asset Performance ManagementPortfolio, targeting the individual requirements andbusiness objectives of our customers by integratingmaintenance consulting with a long term partnershipin a product vendor independent solution.

Our stepwise approach helps you to align the targets ofyour company with your maintenance strategies and toextract maximum performance from your assets in themost cost-efficient manner.You can decide with confidence when to move forwardand implement the necessary steps to improve yourmaintenance performance, reducing the overall risks andfocusing on the right levers.

Implementing our solutions means you can benefit from:

� Improving the performance of your assets and thereforeincreasing the production and the quality of your finalproduct,

� Improving the efficiency of your maintenance processesachieving lower unitary production costs,

� Optimizing your spare parts stocks,

� Improving the lifecycle of your equipment and reducinginvestment requirements,

� Reducing overall energy costs,

� Minimize health and safety related risks.


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Highest

Average

Lowest

Current

1.5 Quality Assurance

2.1 Financial Control

2.2 Equipment Performance Analysis

2.3 Maintenance Review Program

2.4 Health & Safety Management Training

3.1 Organization Structure

3.2 Workforce Involvement and Participation

4.1 Spare Parts Procurement & Material Planning

4.3 Contractor Management

5.1 Standard Procedures and Job Instructions

5.2 Maintenance Management Information System

5.3 Document Control System

5.4 Fault Management

6.1 Operational Analysis

6.2 Maintenance Strategy & Plan Development

6.5 Asset Management Plan

7.1 Maintenance Planning and Scheduling

1.4 Risk Management

1.3 Maintenance Improvement Program

1.2 Maintenance Policy

1.1 Management Commitment and Leadership

7.2 Major Overhauls

4.2 Warehouse Management

4.4 Workshops

6.3 Asset Life Cycle Cost Management

6.4 Plant and Equipment Condition Monitoring

1

2

4

5

3

0

3.3 Personnel Development Program

We have offices at more than 200 sites in 50 countriesworldwide. More than 2.500 employees are working onmaintenance projects.Our maintenance experts have comprehensive know-howand experience, extending across all maintenance relatedprocesses, and provide the right support for your specificneeds. We ensure your success by relying on our:

� International experience and know-how,

� Professional analysis and implementation processes,

� Innovative IT tools,

� Competent and certified consultants and experts,

� Systematic project management.

We help you to identify the potential…Business Based Maintenance uses a professional andstandardized assessment method in the awarenessand analysis phases to measure and benchmark theperformance of your maintenance processes.By identifying the gaps between your actual performanceand the improvements that can be achieved in a giventimeframe, we estimate the improvement potentialand the expected return on your investment.Based on the experience gained in projects all overthe world and many industries, we have identifiedattractive and feasible improvement potential regardingmaintenance costs and production performance.

The average values identified are:

� Cost reduction potential: 7.5 - 10%

� Overall Equipment Efficiency (OEE)improvement potential: 2 - 4%

Siemens' extensive international experience andknow-how ensure the success of our approach

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…and achieve it!By improving the maturity of your maintenance processesduring the implementation phase and assuring thecontinuous improvement and the right level ofmanagement attention in the sustainability phase we cansupport you to achieve and sustain the identified potentialand benefit from it in a short and medium term, basedin our solutions house.

Business Based MaintenanceSolutions House

Change Management & Continuous Improvement

Identified potential:

Equipment uptime Cost Efficiency Capital employed & investments Safety and Environment

Ass

etM

anag

emen

t

Perf

orm

ance

Co

ntr

ol

Pers

on

nel

&O

rgan

izat

ion

Spar

e p

arts

&co

ntr

acto

rs m

anag

emen

t

Mai

nte

nan

cePr

oce

sses

Equ

ipm

ent

Mai

nte

nan

ce S

trat

egie

s

Plan

nin

g &

Sch

edu

ling

Examples of improvement measures are:

� Alignment of the business strategy and the maintenance targets,

� Implementation of Maintenance Management Systems(CMMS),

� Development of preventive and predictive maintenanceplans,

� Training and coaching of maintenance managers, planners and engineers,

� Implementation of a performance control system basedon Key Performance Indicators (KPI),

� Warehouse optimization,

� among others.

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Awareness-Phase

Showing the way towards yourmaintenance improvement.

The awareness phase is based on ourstandardized Maintenance Health Checkassessment, which consists of a 2-day on-siteanalysis performed by our most experiencedconsultants.

This phase is aimed at giving you a clear ideaof the maturity and performance levels of yourprocesses and allowing you to decide withconfidence on whether to proceed with amaintenance improvement project.

The results of this phase are:

� Overview of the maturity of the maintenanceprocesses,

� Identification of the main levers for improvement,

� Rough estimation of the improvement potential,

� Agreement on the next steps.

Business Based MaintenanceA stepwise approach to improve the performance of yourmaintenance processes

Analysis andFeasibility-Phase

In-depth review, risk analysis andsimulation of the return on investment.

Once you decide to proceed, the aim of this phaseis to develop a comprehensive concept for theimplementation phase. The main modules that weperfom in this phase are:

Maintenance Business ReviewAn in-depth assessment that will investigate theimprovement measures needed within eachmaintenance-related process and the interactionbetween maintenance and other functions such asproduction, purchasing and finance. We deliver acomprehensive report with all the findings andrecommendations, a benchmark study on the maturityof your processes and an accurate calculation of theimprovement potential.

Maintenance Business SimulationBased on the results of the Maintenance BusinessReview, this innovative tool can model yourmaintenance organization and simulate theimprovement measures proposed in different “whatif” scenarios. It also performs resource planning andbalancing, verifies the best options and calculates theexpected Return on Investment (ROI) of the project.

Alignment WorkshopOnce the main concept is clear, we organize aworkshop with you to evaluate the concept andthe main risks and challenges to implementthe necessary measures.


� Detailed technical and economic feasibility study,

� Simulation results and estimation of the ROI,

� Implementation concept,

� Overall risk management plan.

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Implementation-Phase

Realizing the improvement potential

This phase is based on our MaintenanceImprovement Program which provides you witha systematic approach to implement all themeasures and realize the identified potential.

Typical activities during the implementation phaseare workshops to develop new procedures,resource planning, training and coaching ofyour employees.

Our project management and professionalsupport ensure that you reach your targets byimplementing the necessary improvements andguiding you through this change managementprocess.


� Professional and improved maintenance processes,

� Organizational and behavioural changes thatallow you to achieve your targets,

� Implementation of new and improved strategies, procedures and tools,

� Realization of the improvement potential, including:

� Equipment uptime and OEE improvement

� Cost efficiency

� Warehouse optimization

Sustainability-Phase

Ensuring long-term continuousimprovement

We can handle your maintenance managementand resources, manage and perform allmaintenance activities. We deliver through aperformance-based contract the results you needto achieve your targets in a long-term partnership,ensuring the management attention required tokeep maintenance performance at the desiredlevel.

This solution, called Integral Plant Maintenance,can include all other phases of the Business BasedMaintenance approach. This means that we canhandle the organization and perform the analysisand implementation of the necessaryimprovements under the maintenance contract.

In addition, we offer a Motor ManagementProgram whereby we manage the maintenanceand repair of all your motors, boosting reliability,reducing costs and cutting inventory levels.


� Improvement in maintenance performance,

� Long-term sustainability and continuous improvement,

� Contractual assurance of the agreed KPI,

� Optimized Spare Parts Stock.

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Customer

Siemens Customer

Subcontractors

Partnership model� Maintenance activities

� Maintenance Management

� Process optimization

� Subcontractor management

� Purchases

� Maintenance resources� Experience and know-how

� Methods and tools

� Maintenance Management

� Maintenance Engineering

� Planning and Scheduling

If you consider maintenance to be a keycomponent of your process expertise but needa partner to manage it, we can offer a jointapproach in which you own part of themaintenance organization that provides youthe maintenance services.In this manner you benefit from having aprofessional and reliable partner to manageyour maintenance processes and resources,concentrate in your core activities and havethe ownership of the maintenance know-howin a medium and long term secured.

Our solution for long term continuous improvement

Long term maintenance contracts are an important andstrategic decision of your company. With our approach wesupport you through the whole decision process anddevelop with you a win-win partnership in which all partsbenefit. Our Integral Plant Maintenance solution is buildup to make sure that we keep the success of this partner-ship, by developing the contract models according to thespecific needs of our partners in performance contractsbased on clear KPI’s.

Among others, the scope of such contracts includes:

� Maintenance Operations including management, engineering, planning and execution,

� Overtake of the electrical and automation maintenance,including the planning, scheduling and improvement processes,

� Management of subcontractors,

� Motor Management Program.

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Business Based Maintenance – no “hit and run”

A successful maintenance improvement approach can never be basedon cosmetic improvements and the implementation of standardprocesses and tools to provide short-term gains.

All maintenance improvement projects have a crucial human factorthat requires change management and constant managementattention.

The risks that the “old processes and manners” will return andefficiency will come back to the levels they were before the projectare high, and all investments and efforts will seem in vain.

Only a professional company willing a long term partnership andwith the right approach can offer the right support to avoid suchproblems. Therefore like in all our solutions, Business BasedMaintenance will guide you through all the improvement processallowing you to make the right and confident decision to moveforward towards a win-win partnership, assuring short and long termperformance.

Siemens can deliver you within our Maintenance Improvement andIntegral Plant Maintenance services innumerous tangible andintangible benefits, including:

� Increase of your total asset utilization, increasing uptime of yourmachines and therefore your sellable production,

� Implementation of new and improved maintenance processes, optimizing and assuring a higher utilization of the available resources increasing the overall cost efficiency,

� Improve on the quality of the maintenance activities, assuring better reliability and longer useful life of the equipments, reducingthe overall investment needs,

� Reduction of your spare parts stocks, the total spare parts costs and increasing your stock reliability by focusing on the critical spare parts,

� Risk mitigation and confidence on the decision making by estimating for every phase the return on investments and analyzingall risks involved,

� Continuous improvement and management attention to keep improving in the long run,

� Increased motivation and competence of the maintenance staff,

� Better maintenance cost control and reporting, increasing transparency and improving the budgeting and forecasting processes,

� Better maintenance planning, improving the production planning,the order to cash and the total supply chain processes,

� By increasing your asset utilization, cost efficiency and in combination with our Energy Optimization solution, we can supportyou to increase your energy efficiency and reduce the overall CO2

emissions.

We help you to make maintenance a competitive advantageof your company:Maintenance – from pure cost factor to a success factor.

We care – that´s our promise!

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SIMAIN Business Based Maintenance is just one service package in our Asset PerformanceManagement portfolio.Within our scope of solutions we also offer Energy Optimization: We can help you to reduceyour overall energy costs.

SIMAIN BUSINESS BASED MAINTENANCE

Maintenance Health Check

Maintenance Improvement

Maintenance Operations Energy Health Check

Maintenance Business Review Energy Optimization Services

Maintenance ImprovementProgram

Energy Optimization ofDrive Systems

SIMAIN ENERGY SERVICES

Motor Management Program

Integral Plant Maintenance Energy Optimization

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www.siemens.com/simain

Order-No.: E10001-T430-A57-V4-7600Printed in GermanyDispo No. 21646 K-No. 38300NOR C-ISOL5208M0901 WS 11091.5Subject to change without prior notice

More Information

Siemens AGIndustry SectorIndustry Solutions DivisionIndustrial TechnologiesI IS INP.O. Box 3220D-91058 Erlangen, Germany

The information in this document containsgeneral descriptions of the technical optionsavailable, which do not always have to bepresent in individual cases. The requiredfeatures should therefore be specified in eachindividual case at the time of closing thecontract.

All designations used in this document canbe trademarks the use of which by thirdparties for their own purposes could violatethe rights of their owners.

© Siemens AG 2009All rights reserved.

simain business based maintenance · many companies still see maintenance only as a cost factor....

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