Maintenance with foresight - Bosch Packaging€¦ · on the results of a previous technical ......
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Avoiding downtime Since the earliest days of production at their Luxembourg facility, Chemolux has systematically applied a Just-in-time (JiT) production strategy. “Rather than producing goods in advance, we focus on producing precisely the required amounts for exactly the time they are needed,” explains Philippe Gosset, Plant Director at Chemolux. Benefits of this strategy include a decrease in over- production, shorter lead times and lower transport costs. JiT is an obvious solution for a company that has no dedicated storage space and can store no more than half a day’s production output. However, the strategy is not wholly without risk. Even minor mechanical faults can quickly lead to unplanned downtime, forcing production to cease at very short notice. To mini- mize these risks, Chemolux and Bosch Packaging Services have developed a preventive maintenance strategy based on the results of a previous technical audit. 20 | packazine Customers & Markets Pharma Maintenance with foresight To improve the effectiveness of their production processes, Chemolux has introduced a preventive maintenance strategy developed in partnership with Bosch Packaging Services. Today the Luxembourg-based manufacturer of machine dishwashing powders and tabs produces without unplanned downtime and with significant reduction in costs.
Transcript of Maintenance with foresight - Bosch Packaging€¦ · on the results of a previous technical ......
Avoiding downtimeSince the earliest days of production at their Luxembourg facility, Chemolux has systematically applied a Just-in-time (JiT) production strategy. “Rather than producing goods in advance, we focus on producing precisely the required amounts for exactly the time they are needed,” explains Philippe Gosset,
Plant Director at Chemolux. Benefits of this strategy include a decrease in over-production, shorter lead times and lower transport costs.JiT is an obvious solution for a company that has no dedicated storage space and can store no more than half a day’s production output. However, the strategy is not wholly without risk. Even minor
mechanical faults can quickly lead to unplanned downtime, forcing production to cease at very short notice. To mini-mize these risks, Chemolux and Bosch Packaging Services have developed a preventive maintenance strategy based on the results of a previous technical audit.
20 | packazine Customers & Markets Pharma
Maintenance with foresightTo improve the effectiveness of their production processes, Chemolux has introduced
a preventive maintenance strategy developed in partnership with Bosch Packaging Services.
Today the Luxembourg-based manufacturer of machine dishwashing powders and tabs
produces without unplanned downtime and with significant reduction in costs.
2006
Imp
rove
men
t
Machine efficiency
Legend: preventive maintenance improvement
Maintenance costs
2008
+13%
–11%
2011
packazine | 21
Optimized performanceIn a first step, the modernization of older equipment led to state-of-the-art technology being introduced on all lines. In a second step, a dedicated preventive maintenance program was implemented resulting in long-term sustainable improvements. “Chemolux operates in a very dynamic market, products are changing fast. For this reason, high flex-ibility and continuous improvement of our production processes are absolutely crucial,” says Ludovic Ghesquière, Maintenance Manager at Chemolux.The aggressive chemical production environment and high operational speed of all machines, throughout several shifts per day, necessitate frequent exchange of wear and tear parts and short main-tenance intervals. Bosch’s preventive maintenance service package ensures that required maintenance is conducted at the appropriate time and at regular intervals, on all 15 lines.
Small intervals, huge effectThe biggest challenge at Chemolux con-sisted in finding the right maintenance
intervals for all lines and implementing the new maintenance concept within the organization. The fact that both companies had successfully worked together for 15 years and that Bosch Packaging Services already had an intimate knowledge of Chemolux’s business processes proved to be a great advantage for both sides. Following an intensive implementation phase, first positive results became visible. “No major stops have occurred during the past five years,” says Phillippe Gosset. “In addition, maintenance costs have decreased and efficiency has increased by a two-digit percentage.”The machines are checked and cleaned per shift, day, week or month, depending on the requirements of the individual lines. “Thanks to the scheduled intervals, we have complete control over our lines and can deliver a high level of service for our customers,” Ludovic Ghesquière observes. The organization of mainte-nance activities is now much smoother and more predictable, resulting in reduced costs. A detailed evaluation of the Preventive Maintenance program
demonstrated an 11 percent decrease in costs between 2008 and 2011, while machine efficiency increased by 13 percent during the same period.
Collaboration based on partnershipThe establishment of the Preventive Maintenance program also had the positive side-effect of intensifying the relationship between Chemolux and Bosch. Regular inspections are always carried out by the same Bosch maintenance technicians with Chemolux-specific expertise. “Today, we achieve faster product changeovers and have real experts working on our machines,” says Philippe Gosset, to which Ludovic Ghesquière adds: “Our goal was to switch from a customer-supplier relationship to a real partnership – and we have achieved this to our complete satisfaction.”
For more information please contact:
Claudio Manfroni
Phone: +41 58 674 73 98
E-mail: [email protected]
