The Challenge

The client was seeking to be recognised as a cost-effective producer and a leader in asset management practices amongst its peers in Africa.

Another objective was to have reliable operations and reduced unplanned downtime. The client's maintenance management were outsourced to a 3rd party. At the same time, the client was migrating to a new EAMS/CMMS.

The client sought the services of a consultant to develop and implement an effective asset management strategy for its operations.

The Solution

A maturity assessment of the mine's asset management (AM) system was conducted: to highlight gaps in relation to ISO 55000 assessment covered both mining and processing plant operations.

Developed a new AM strategy:

• Vision and mission that's aligned to the business strategic goals.
• A strategic roadmap to close the gaps.
• Reliability elements covering the entire asset life cycle were developed.

Asset tactics development stream included:

• Historical asset failure data analysis
• Plant assets criticality review and analysis
• RCM analysis / FMEA workshops
• Existing asset tactics review
• Development of optimised PM programme
• Client validation and final sign-off

Results

Key notable results included:

• Asset Management Strategy, Policy and Plan development & implementation
• 24-month strategic improvements roadmap aligned to ISO 55000
• 2% improvement in plant availability within 6 months into the project
• 5% reduction on maintenance spend
• FMECA-based maintenance strategy
• Work Management process definition
• Operate for Reliability elements
• RCA and Defect Elimination training
• Change Management support