Shipyards & Container Ports

The five biggest challenges of the Shipyards and Container Ports industry is facing are improved safety performance, greater operational complexity, congestion risk management, ability to stay profitable and ultimately doing more with less space.

The shipyards carry out the repair of vessels and the construction of offshore equipment. Production planning, a lean logistics chain, meeting deadlines through effective project management, designing 5S layouts, innovative products, such as asset tagging, and the development of multidisciplinary human resource skills are essential.

It is simply not possible to create an effective production process without a robust plan to maintain equipment to the highest possible standards and performance. Yet, our work with certain clients, over the years, has shown this is exactly what occurred!

Automotive

Automotive manufacturers are facing the increased challenges of developing a large modular product offer. Additionally, with many different user types preferring vehicles specified for their individual preferences, managing this vast level of complexity and product variation presents an enormous array of business-critical challenges.

The global automotive manufacturing industry is growing and with that comes the need for evolution and change. To combat these changes, clients need an effective build line that is able to respond to the changing priorities and varying rates of flow. The process operation must become simpler and more robust with reduced waste – in particular – waiting time and overproduction.

MCP offers a range of Continuous Improvement (CI) services including Lean Practitioner, Kanban systems, Rapid Changeover, Kaizen, Process Mapping and Problem-Solving using RCA, OEE and Total Productive Maintenance (TPM).

Continuous Improvement is a proven method for identifying opportunities to enable manufacturers to minimise the cost of complexity throughout their operations and to harness product variation as a differentiating strength in their marketplace.

Pharmaceutical

The Pharmaceutical sector is dominated by a limited number of very large global groups, where innovation and science play a crucial role.

The context of the healthcare market and the industry’s main priority is the provision of safe and effective products. In this highly regulated environment and sterile manufacturing facility, the demands of compliance to regulatory standards are achieved through a robust and efficient production processes.

Improvement programmes, asset management optimisation and methodologies are enablers to support the improvement of the internal logistics processes, to optimise OEE and maintain the ‘clean environment’ to a very high level.

Previous experience in this sector has included the development of reliability excellence programmes that ensure work streams are put in place to manage the maintenance programme. AMIS assessments are usually completed as a 'framework approach' to achieving World-Class within a target of 5 years. Documented results frequently report less than 4% corrective maintenance with compliance is completed 100% on time.

Food

In an increasingly competitive landscape, food companies involved in new product development and manufacture are facing more and more challenges. Many are linked to the production and marketing of final foods or ingredients used in their preparation and relate to meeting changing consumer demands.

Often, this needs to happen quickly with costs kept to a minimum. For the main part, demands include cutting costs, bringing products to market quickly and staying compliant with a large number of regulations. What remains a constant challenge is maintaining the best methods of storing, packaging, preserving and distributing products.

When industry changes make for a more competitive marketplace, manufacturers look to their supply chain to be as cost effective whilst delivering a safe quality product.

Over the years MCP has helped clients with their efficiency and offered reliability programmes that deliver in a structured way to ensure the security of supply within a known cost base and continuous improvement framework. Proven results have reported improved efficiency that enables change to shift patterns that make significant reductions in the cost of labour.

Chemical

It is a tough environment for the chemicals sector currently; however, there are many opportunities for growth increasing over the long term. The issues challenging businesses are the same issues in which growth is most likely to occur.

Companies produce industrial chemicals for use in the formation of new substances. Resource scarcity and climate change, technological advances, shifts in global economic power and rising customer expectations are forcing the Chemicals Industry to adjust. They’re restructuring their organisations, increasing their customer focus, and trying to build distinctive capabilities that provide a competitive advantage.

When clients recognise key issues such as reactive workloads, high percentage breakdowns, poor cost control, high downtime and production losses and poor maintenance information system – optimised OEEs is a key solution to the reliability and availability of equipment. Additionally, a critical business solution is ISO 55000 Certification that undoubtedly in time will become mandatory.

Aviation & Aerospace

The Aviation and Aerospace Sector is an industry that employs millions of people, around which various businesses have developed. Large airports and their infrastructure require a highly optimised maintenance strategy, integrated computerised maintenance management systems (CMMS) and effective maintenance plans – to ensure the maximum availability and reliability of equipment as well as the profitability and safety of goods and people.

Time is one of the highest priorities for every airport across the world, which means operations must be highly efficient and ultimately streamlined if the ancillary services are not to impact on the customer experience of this busy environment.

MCP’s experience in the transport sector and other complex ‘live’ environments, such as Aviation, is a key factor for clients in this industry when engaging MCP. The result of using an AMIS (Asset Management Information Service) benchmarking system, is to identify significant opportunities for improvement. These initial assessments include engineering systems current status, methods, skills and management information and will be carried out across various departments.

The outcomes of a change programme of this nature will ensure the increased reliability of assets, the reduction of costs against forecast budgets, improved skills and competency of the workforce without the need for redundancy or job losses.

Drinks

The global alcoholic beverage market is the UK’s fastest growing sector with whisky, in particular, gaining huge popularity across the globe. However, the logistics of producing in this multibillion-pound industry are unlike any other food and beverage sector, especially if the manufacturer is looking to expand their product line and keep pace with demand.

Product development plays an important role in this sector, as the packaging phase is complex due to the diversity of existing formats. The optimisation of the packaging lines, the level of their availability and efficiency (OEE) and the optimisation of cycle times are essential.

Often companies recognise that there is a ‘firefighting culture’ to the maintenance teams work. There are issues around stock accuracy, parts availability, poor productivity and these constraints effect capacity within the production environment. An AMIS assessment can indicate the core areas of focus, for example, a new CMMS system, the alignment maintenance team, stores booking accuracy and on-going continuous improvement plans.

To reach World-Class, any maintenance department must achieve outstanding results with improved engineering downtime of less than 2.5% and increased reliability of equipment. This has a direct correlation with MP increasing output per minute and improving cost reductions, whilst the entire process will improve the morale within the team.