Contributing Re.engineer Partner: Noria Corporation (www.noria.com)
Challenge: The Simmons Feed Ingredients plant in Southwest City, Missouri, produces high-quality animal nutrition for pet food, aquaculture and livestock. Some time ago, the facility was experiencing one equipment failure after another, with some costing in excess of $200,000. The ensuing reactive maintenance work resulted in parts being ordered for machines that broke down a day earlier and work orders being generated to fix the “Band-Aided” equipment during the next scheduled downtime. The Simmons solicited the support of Noria consultants to develop a roadmap for lubrication excellence. After implementing Noria’s Lubrication Program Development and training, the facility was able to achieve cleaner oil, prevent machine failures, avoid lost production and save up to $1 million a year.
Solution: When Simmons decided to put more of an emphasis on lubrication, changes began to be made within the organization. Once the basics were in place, the company chose Noria Corporation for its training and Lubrication Program Development (LPD). Noria’s experts developed a roadmap for lubrication excellence, including precision lube routes, proper oil handling practices and written procedures for each task.
Simmons discovered that it had been using all the wrong types of oil. Recommendations were made for installing filtration units, desiccant breathers and color-coded identification systems for machines and oil transfer containers. A new lube room was also designed to keep oil in a climate-controlled environment.
Results: After the implementation of the LPD program, Simmons achieved 50% reduction in downtime and significant culture change.
Impact: Potential cost savings of $1 million per year