The Situation
A large asphalt plant in Oxfordshire had recently appointed a new Production Manager who was tasked with improving the OEE of the site. The majority of equipment and machinery on site had been previously used at the customer’s other facilities and refurbished. As a result, the customer had no details on critical spares and their supply lead times. Production had been running over-capacity, making any proactive planned maintenance downtime impossible to come by.
The Solution
The team from the customer’s local HAYLEY DEXIS branch invited NSK to visit the plant to compile a full process map of on-site critical assets and applications, as part of their AIP added value programme. The survey process took place out-of-hours and identified all current asset designations with suitable replacements recommended, including their estimated lead times. Experts from the Hayley DEXIS dedicated Drives division also attended the site survey to cross reference the gearboxes and motors at the asphalt plant with contemporary models also recommended.
"THE OVERHAUL HAS ACHIEVED THE AIM OF IMPROVING OVERALL EQUIPMENT EFFECTIVENESS ON SITE."
The Result
The full process map report (PM01399) outlined, in detail, the asset and replacement bearing recommendations, with drive train components covered in a separate report from HAYLEY DEXIS. The insight that these reports have provided has enabled the new Production Manager to remove old equipment on lengthy lead times and replace it with modern, more reliable technology. This overhaul has achieved the aim of improving OEE. Having decided to purchase all critical spares to hold locally, the customer has minimised the risks associated with supply delays extending any failure-induced downtime.