Reliability Improvement

Autocraft Drivetrain Solutions provides remanufactured diesel and petrol engines, transmissions and machined components to global automotive OEMs. They have an established maintenance team and wanted to improve the visibility of maintenance Key Performance Indicators (KPIs) and the reliability of their most critical assets.

PEME conducted an initial Assessment to establish the ‘gap’ between existing arrangements, best-practise and client aspirations.  A tailored, Reliability Improvement solution was then scoped for critical assets that included:

  • Provision of new Preventive Maintenance routines that address historical failure data.  PEME have developed a Fast-track Reliability Centred Maintenance (RCM) approach that allows rapid generation of Preventive Maintenance schedules whilst complying with best-practise RCM principles.  The new maintenance routines have focussed and quantitative task descriptions with inspection criteria and access requirements detailed.  This led to improved maintenance delivery
  • Asset surveys with recommendation provided to immediately improve asset condition
  • Implementation of a full Condition Monitoring programme to identify degradation before machine failure.  This includes vibration analysis, thermography, acoustics and oil analysis and has allowed several potential failures to be addressed before machine failure.  This also includes a monthly asset condition check to find failure modes to allow corrective maintenance to take place
  • Training of Autocraft engineers to produce future maintenance task improvements
  • Development of a bespoke software tool to provide:
    • Maintenance KPI dashboard
    • 3D model of plant illustrating asset location
    • Operator interface to report defects
    • Scheduling of Operator, CBM and maintenance tasks
    • Preventive, Statutory, Corrective and Reactive Maintenance management

Autocraft achieved the following Benefits:

  • 33% reduction in breakdowns
  • 31% improvement in remedial tasks completions
  • Annual recovery of 4,000 hours of lost production capacity
  • Increased visibility of maintenance KPIs
  • Improved evidence audit trail for ISO9001 and ISO14001 audits