Maximizing Efficiency: Boosting Plant Productivity and Reducing Maintenance Costs Worldwide
Overview: The client is a multinational conglomerate with
diverse operations in Chemicals, Shipping,
Engineering, and Foundry, generating around $1.5
billion in annual revenue. With manufacturing
facilities across Mexico, Egypt, and India the
client needed a streamlined solution to enhance
plant maintenance planning and cost
management across locations.
Objective: Implement a comprehensive solution to enhance plant maintenance planning, improve budget tracking, and enable
real-time monitoring of material usage and contract activities. The primary goals were to achieve cost efficiency in
maintenance, gain real-time visibility into budget allocation, and facilitate daily tracking of contract costs. This
initiative aimed to improve decision-making and boost productivity across their global operations.
Business Challenges
The client faced operational challenges in managing and maintenance planning of their plants across multiple
locations globally, which impacted their efficiency and cost management. The specific business problems
included:
Lack of Maintenance Visibility: No interactive system to track maintenance activities, budget planning, & expenses
Cost Tracking Gaps: Inability to monitor material consumption costs by department and plant
Contract Activity Monitoring: No system for daily tracking of contract-related activities and associated costs
The Solution
To tackle the client’s challenges, we deployed a comprehensive SAP Plant Maintenance (PM) solution and on
top of it incorporated industry best practices and a real-time interactive dashboard that enhanced visibility
into maintenance activities. The solution addressed the client’s previous issues with tracking systems and
elimination of manual processes by integrating maintenance orders, contract activities, and fund
management. The implementation of this system not only streamlined maintenance planning but also
improved decision-making at all levels.
Value Delivered
Our solution helped the client tackle their plant maintenance challenges, resulting in improved operational efficiency.
Our streamlined processes generated significant cost savings and enhanced decision-making. This increased
transparency fostered greater satisfaction and control within the organization, ultimately driving better outcomes.
100%
Real-time tracking enabled better budget management and cost control
95%
Optimal tracking and management of the Plant Maintenance budget
Automation enabling quicker decision-making and resource allocation