The request: perform a thorough analysis of Shin-Etsu's maintenance organization and processes and pinpoint potential improvements across the board. Maintenance costs had to be reduced significantly in the short-to-medium-term, without compromising on delivery reliability, quality or health, safety & environment.
- Identify Key Performance Indicators in areas such as outsourcing, maintenance concepts, technician efficiency, gatekeeping and purchasing.
- The ‘quick-win’ objective was to eliminate the greatest losses and to generate flow.
- At the core of the new approach was the shift from "firefighting mode" to proactive planning.
- The adaptation of existing concepts to arrive at lowest maintenance costs and the channeling and assessment of maintenance requests from both production and technical services.
- Clear operational and program goals agreed upon.
- Setting up of system for (daily) consultation concerning deviation from norms and steps to correct those.
- Average projected double-digit reduction of maintenance costs over four-year period,
- 90% of which achieved in first two years,
- Maintenance process performance improved,
- Performance management systeem integrated and bearing fruit.