Developing a reliability-centered maintenance approach
Eurasian Resources Group S.à r.l. (ERG) is a leading producer of natural resources, with integrated mining, processing, energy, logistics, and marketing operations in 15 countries. Founded in 1994, the company comprises one-third of the metals and mining sector in the Republic of Kazakhstan, and it contributes significantly to the country’s social and economic development.
The diversity of ERG’s businesses led to a large and varied collection of equipment assets responsible for supporting production processes. Despite costly, time-consuming maintenance efforts, the company experienced repeated equipment failures and unplanned downtimes. A lack of transparency compromised decision-making on maintenance issues.
ERG wanted to develop a reliability-centered maintenance (RCM) approach that would improve equipment dependability, reduce repair costs, and increase the efficiency of maintenance processes – without negatively affecting asset performance. The company also needed to elevate asset maintenance in the minds of workers and in the corporate culture.
Because it had already deployed the plant maintenance component of the SAP ERP application, ERG possessed an extensive asset maintenance history. To manage its production assets more efficiently, the company hoped to build an end-to-end process – extending from top management to the shop floor – that would balance asset reliability and maintenance costs.