In order to stay compliant with changing quality management standards, Polinter, a Venezuelan petrochemical company, considered implementing an asset performance management (APM) program. The goal was to better streamline various data systems to reduce costs, improve Operational Excellence, and remain competitive.
After the implementation of ISO 9000 for quality management, which calls for optimally and sustainably managing assets and asset systems, their associated performance, risk, and expenditures over their life cycles, Polinter sought to drive continuous improvement. It had been certified with ISO 9000 for more than 21 years, and recognized the need to adapt its quality management program into an APM system.
To do so, Polinter reviewed and adopted best practices from international standards and reliability methodologies to improve asset performance and availability. The team documented its transformation through the creation, modification, and elimination of asset-related work processes.
The company also recognized the importance of the human factor and workplace culture in its transition to an APM-driven organization. For each process that the team implemented, Polinter included training in all methodologies and involved end-users in every step of the project. The organization’s full participation helped to guarantee the success of the project.
One critical part of merging Polinter’s quality management and APM programs together included incorporating a reliability process into existing quality management processes. It required input from the production, maintenance, technical, and reliability teams about recommendations for improvement. As a result, Polinter developed four sub-processes:
• Asset definition and classification
• Asset strategy management
• Asset performance evaluation
• Recommendation management
These processes are driven by Predix Asset Performance Management (Predix APM) (formerly Meridium Enterprise APM) and support a continuous loop of improvement.
As a result of developing a single APM program incorporating both quality and asset management, Polinter improved the mechanical availability in two out of three of its plants. Additionally, between 2012 and 2015, Polinter reduced corrective maintenance actions by 14% and increased preventative maintenance by 25%.
Additional benefits include:
• Increased client satisfaction
• Increased motivation of personnel
• Efficient use of resources
• Increased capacity to focus efforts on key improvement opportunities
Learn more about Predix APM and how it's enabling industrial organizations to realize significant business outcomes.