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Maintenance is vital to a company’s development and success. An innovative maintenance strategy exhausts all available technological possibilities and related potentials as well as their holistic integration into the process landscape.

Conventional maintenance strategies are firmly established, and they will continue to play a role in the future. However, conventional maintenance concepts do not fully meet the needs of today’s asset intensive industries: they bind capital and expend resources to a high degree. Due to an increase in the networking capabilities of machines and the increasing importance of IoT as well as the provision of data, innovative maintenance strategies are gaining significant importance.

Resource-conserving, efficient, fail-safe and high quality are words to describe innovative maintenance strategies in asset intensive industries. The primary focus is on the sensible and efficient use of modern technologies as well as the knowledge hidden in technical systems (in the form of collected data and information). Digitalization has generated novel possibilities for the maintenance of machines, devices and complete production lines, and it permits further process integration in internal and cross-company networks.

Recurrent topics within the process industry are the reliability of plants, data and processes, the digital transformation and mobilization of processes, asset life cycle management (from planning to construction and operation, re-powering and ultimately to the dismantling of the plant) and the management of spare parts.

Maintenance & Asset Performance

By combining our consulting expertise in the development and implementation of adequate maintenance processes and independent technologies as well as their operational implementation, we are able to offer our customers in the chemical industry comprehensive solutions with the following focal points:

Maintenance optimization

  • Optimization of the maintenance organization (production centric and/or customer centric)
  • Optimization of the maintenance processes (leading practice, process automation, )
  • Collaboration between engineering, production, sales, suppliers and service (configuration management, digital twin, asset intelligence network)
  • Provision of required resources for planned maintenance; mitigating demand peaks with additional, reactive maintenance

Digital Transformation/Mobilization

  • Mobile maintenance (mobilization of processes and mobile solutions)
  • Digitalization of the maintenance processes (process automation, digitization of processes through remote monitoring, IoT)
  • Digitalization in the area of knowledge management (technical documentation, manuals, etc.) and visualization (3D models for spare parts catalogs, augmented reality, digital twin)

Reliability Management

  • Improving equipment reliability by orientating maintenance management accordingly, triggering the transformation to a high reliability organization
  • Efficient and reliable processes form the basis for a reliability centered maintenance
  • Innovative technologies and measurability (KPIs and statistic evaluations) facilitate transparency and optimization

Predictive Maintenance

  • Increase of asset/equipment availability, enhancement of maintenance processes
  • Smart assets and connectivity combined with predictive analytics (monitoring, analysis, pattern recognition and derivation of appropriate measures) facilitate increased availability and reliability

Spare Parts Management

  • Service level (spare parts) based on defined plant/asset availability (reorder points, equipment pooling, asset intelligence networks, service chain optimizer (SCO), …)
  •  Demand-oriented provision of spare parts (equals a reduction of unavoidable downtime and equipment limitation)
  • Definition of relevant channels of supply
  • Specification, harmonization, standardization of spare parts (eClass, etc.)
  •  Reduction of tied-up capital

BearingPoint’s comprehensive advisory approach is based on the following four factors:

  • Strategy
  • Organization
  • Processes
  • Tools/ IT

How BearingPoint adds value:

We help clients achieve maintenance excellence based on strong improvement levers, including:

  • Reliability: We help you to leverage your equipment knowledge within the company to determine the right strategy to apply.
  • Flexibilty: We develop appropriate business rules to optimize the completion of scheduled tasks and to deal with random breakdowns.
  • Balance: Conflicting goals between engineering, production, purchasing and maintenance performance need to be balanced. We adopt an approach based on the total cost of ownership (TCO) during asset life cycle phases.
  • Added value: We encourage the mindset of maintenance as an added-value service to evolve within the company, with the objective of ensuring the expected equipment availability.
  • Compliance: We ensure compliance with environmental regulations.