Success case ■

Assetsman has completed more than 1,500 industrial asset management projects for its clients. Discover some very interesting results obtained by our customers through the studies presented below.

For each completed project (Success Case), we tell you:

The client's industry
The context of this client's project
The problem identified and the methodology used to meet the client's needs
And above all the tangible results that we were able to obtain for the client

We are listening to you to better detail these studies and their results, hoping to be able to bring you our experiences and skills to help you find sources of effective and concrete gain.

Renewable energy

Renewable energy production assets renewal plan

Client's Needs

The company specializing in the production of hydroelectric renewable energy has a fleet of around twenty alternators for which the question of renewal arises.

A renewal plan was therefore considered, taking into account the lifespan estimated by the manufacturer, to maintain the expected production performance of these alternators.

A budgetary and organizational constraint specific to the company only allows for one alternator replacement every two years.
The company wishes to estimate the exposure to the risks to which it was exposed given these constraints

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Assetsman's solution

ASSETSMAN proposed solutions using its ASSETSVALUE tool (decision-making tool in the management of asset management). By carrying out Risk / Cost optimization studies, ASSETSMAN was able to provide precise calculations for:

• THE ACTUAL LIFE of the alternators based on the modeling of their reliability.

• Determining the opportune moment of identical replacement of the alternators and estimating the LACK OF WIN if we shift from this optimum

• THE GRAY DEBT* to which the company is exposed with its current organizational constraints.

* gray debt: cumulative shortfall generated by renewal deferrals.

■■■■

The ACTUAL LIFE is

%
longer than the lifespan estimated by the manufacturer

The FAILURE TO WIN given the current renewal plan is equal to

%
of the replacement value for each alternator*

*worth a few million euros

The GRAY DEBT equals to

%
of the replacement value of the fleet * in the current renewal plan

* fleet of around twenty alternators

Oil & Gas

Optimization of the intervals of preventive maintenance

Client's Needs

The interval of preventive maintenance of equipments is a problem for the client.
He follows the orientations of the manufacturer, replacing the equipment every 10 years
When noticing a level of the tool failure of 5% before 7 years, he wants to reconsider the intervals of preventive maintenance.
The restrictive conditions for the tooling maintenance are the following:
• Replacement cost : 470K€
• Intervention time : 10 days

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Assetsman's solution

Assetsman's team used its calculation algorithm* to:
• Value the cost of the current preventive maintenance task
• Define the interval of maintenance for the lower cost
• Value the gain between Assetsman's results and the current policy of the client

■■■■

New interval of preventive maintenance calculated:

Replace the tool

years

Economy of

K$ / year

Compared to the current situation

years

Economy of

K$ / year

Compared to an interval of preventive maintenance more strengtthened :

Energy

Optimization of the spare parts or inventory management

Client's needs

Policy of spare parts stock considered very conservative by the client.
He wants to implement an evaluation and optimization of the stock policy to obtain economy.
The study involves 45.000 spare parts, 3 power generating plants and 10 independet substations.
The stock policy currently is cautious, since the client has to assure the continuous supply of electricity and water.
The client's objective is to define which spare parts should be reduced, kept, or raised.

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Assetsman's solution

Assetsman's team used Assetsvalue to:
• Value the client's current stock in terms of cost and risk
• De fine a level of consented risk for the client
• Resize the stock based on this consented
• Define a new policy for spare parts stock
• Value the gain between Assetsman's results and the current policy of the client

■■■■

Obtained economy with the new stock policy

Résultats

Paper and Pulp

Optimization of maintenance major shutdowns

Client's needs

The client wants to reduce the cost of annual maintenance major shutdowns at the lower risk.
Two cases to deal with regrouping 70 equipments of 4 different families.
The cost of the current major shutdowns is between 1 and 4 million euros (3 shutdowns / year).

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Assetsman's solution

Assetsman's team used to:
• Value precisely the cost of annual major shutdowns
• Determine for each task the right moment to be done
• Direct all tasks to a commom Optimum with the best trade-off risk / cost
• Value the gain between Assetsman's results adn the current policy of the client l

■■■■

Simulation of

Different preventive maintenance tasks

Planning

out of

shutdowns per year or 1 shutdown less per year

Economy of

% over the annual costs of the major shutdowns

Steel

Optimization of maintenance major shutdowns

Client's needs

The equipment availability is considered inadequate by the client.
He wants to implement an approach to improve the availability of production equipments and, particularly to:
• Reduce failure rates
• Reduce recurrent malfunctions
• Reduce the periods of unavailability due to preventive maintenance

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Assetsman's solution

Assetsman's team used Assetsvalue to:
• Implement the method CBA (Core Business Analysis): identification of the equipments that obstruct reaching the availability objectives (bottlenecks)
• Carry out trainings of the methods RCM and RCA (over 100 people trained)
• Carry out pilot studies for relevant workshops
• Follow the teams as part of the development of the approach RC< and RCA in the plant

■■■■

Reduction of

% in the operations of maintenance control and review of TPM standards

Gains of

hours of workforce/year

Reduction of unavailability of equipments for preventive maintenance of around

hours

Airports

Support for the preparation to the certification ISO 55001

Client's needs

Concern with the image of brand and marketing communication with the interested parts and aviation professionals.
The client wants to show the efficient asset management to the regulatory authorities.
To do that he needs to create a system of asset management according to ISO 55001.
Stating the approach in the second semester of 2014.

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Assetsman's solution

Assetsman's team used its expertise on the standard ISO 55001 to:
• Carry out a diagnosis using the maturity scales provided by the IAMS method (interactive assessment for asset & maintenance strategies)
• Develop and implement a master plan of Asset Management
• Set up an asset management system
• Train and monitor teams (one hundred professionals trained)
• Carry out pilot studies (RCM/LCC…) that legitimize the appropriate beginning of the master plan and enable to get the first gains

Certification ISO 55001 obtained by the client in less than

years

Support to the teams

trained people

First economies
achieved thanks to
pilote studies

Chemical Industry

Prioritization of investment projects according to the approach risk / cost

Client's needs

The client has 40 investments projects to carry out, half of them are considered urgent and with a high added-value.
Incapable of carrying them out immediately (annual budget restricted), the client needs an alternative investment plan in the next 5 years.
He wants to prioritize the investment projects (CAPEX) taking into account the trade-off between risks and costs.

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Assetsman's solution

Assetsman's team used its calculation algorithm to:
• Define the appropriate moment to carry out the investment projects (LCC)
• Determine the losses due to the anticipation or delay in the conclusion of the projects
• Elaborate different scenarios of investment to find the most appropriate one regarding to the client's needs (budget limits)
• Help the client choose the scenario according to the trade-off risk / cost