PolymerLatex cuts maintenance costs

16 September 2008

UK Polymer producer PolymerLatex says it has cut maintenance costs by 10 per cent.

PolymerLatex’s Bromsgrove site, where the company claims to have cut maintenance costs by 10 per cent
PolymerLatex’s Bromsgrove site, where the company claims to have cut maintenance costs by 10 per cent

The savings were made at the company’s Bromsgrove site two years after embarking on a five-year performance based contract with ABB’s Full Service team.

Under the terms of the agreement, ABB is responsible for all maintenance-related activities and equipment at the plant. It manages the operations against agreed targets and incentives for plant performance and total cost of maintenance.

PolymerLatex UK had identified by internal benchmarking the need to bring its maintenance operation to current best practice.

Andreas Ostrowicki, managing director, PolymerLatex UK, praised the service agreement saying it provided 'an overview of best practice from all over the world'.

He described the old system as too reactive.

'ABB has allowed us to benchmark our maintenance system and to make us aim for best practice. They have helped us identify faulty equipment, installed systems designed to drive costs down and implemented a truly proactive approach in maintenance,' he added.

ABB has introduced tools to measure plant efficiency such as Overall Equipment Effectiveness (OEE).

Ostrowicki said: 'Initially they have helped our manufacturing improvement teams to work better and introduced some valuable ideas to improve manufacturing efficiency'.

The contract is based on a five-year improvement plan. The agreement between PolymerLatex and Full Service specifies three main key performance indicators (KPIs), covering cost efficiency, service level performance and the technical availability of plant. A number of other KPIs cover such issues as the level of spares inventory.

Ostrowicki continued: 'This service agreement is in place to deliver cost control and optimisation and improve manufacturing efficiency.'

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