AMIS Drives Improvement for Brewery
Asset care and maintenance have been key to sustained improvement in performance for drinks manufacturers. Thanks to MCP’s Asset Management Improvement System (AMIS), which assesses an organisation’s operations and asset management with the focus on driving improvements and benefits, this can be achieved.
One of our brewery clients conducted a global initiative to reduce their maintenance costs and improve reliability within their factories. With our support they adopted AMIS. Following the initial, in depth assessment, they only achieved an AMIS score of 33 percent. However, through continuous improvement projects a huge improvement in plant performance, reliability and efficiency were achieved, which was reported through regular auditing.
Achieving World Class
After a number of years, the brewery client achieved an AMIS score of 80 percent (World-Class), placing them in the top three percent of all 6,000 AMIS participating sites. The score was also well above the drinks sector average of 45 percent.
This is how they achieved success with AMIS:
Only by completing a series of annual assessments and continuous improvement projects could the brewery achieve this success.
One of their main improvements followed an annual AMIS assessment where an old existing sieve, that generated a lot of waste and had a high associated cleaning cost, was replaced with a new sieve, which was easily cleaned and maintained.
Another was to replace obsolete software at the tanker station with standard Siemens software. This allowed the engineering department to have greater input into plant modifications and improvement initiatives.
Continued Improvements
A year later a boiler control was modified to a software-based system which led to greater efficiency and reduced running costs.
An analysis was carried out on the plant which identified a crucial control path for production. Based on this, duty standbys were installed for the whirlpool and wort stripper pumps meaning that production would not be interrupted and stalled due to any failure of these pumps in the future. This resulted in a decrease in downtime, since the installation of both pumps.
The hot and cold liquor pumps in the brewhouse were also identified as regularly requiring maintenance interventions and were replaced with new pumps. These contained more efficient motors and seals which were easier to replace.
The Head of Operations at the site said:
“The AMIS Journey to World Class has been key to major, sustained improvement over the last four years.
We have seen significant reductions in utility ratios, site waste and overall conversion costs through this journey. We have also seen full site engagement with remarkable contributions from all: including engineering, production, laboratory and indeed our contractor partners. This journey and the continued personal development and achievements of all in the brewery is something we are very proud of.”
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