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Client: Incorporated in 1884 and headquartered in Milwaukee, Wisconsin, Joy Global is an industry-leading manufacturer and a supplier of advanced equipment, systems, and solutions to the global surface and underground mining industry. The company runs its business operations in 135 locations across six continents and markets a range of high-performance, yet productive, machinery and solutions used extensively for the mining of coal, copper, iron ore, oil sands, gold, and other mineral resources. Joy’s lifecycle management programs not only help mining companies maximize the productivity and life of their equipment, but also offer services including 24/7 emergency repairs, preventive maintenance, performance-enhancing upgrades, rebuilds, and relocations.
Challenge: Joy’s fleet of heavy machinery was managed using the IPSECA (identify, plan, schedule, execute, close, and analyze) maintenance model; however, the three components such as identification, close, and analyze were constantly found to be underperforming. Implementing SAP for the computerized management maintenance system did not help Joy tackle the issue, with the identification component still found to be weak.
Faced with the task of eliminating the complications and inefficiencies in its workflow and minimizing scheduled and unscheduled machine downtime, Joy Global decided to implement asset performance enhancement (APM) solutions that can help streamline its business processes and optimize machine reliability and uptime. Joy selected GE Digital’s APM software solutions after having a closer look at the different APM offerings available in the market.
Solution: Built on an innovative platform, the APM suite of solutions use intelligent asset strategies to constantly monitor and analyze asset condition data, enabling the management to create automated actions and strategies to improve the asset performance & availability, reduce production losses, and lower long-term incident costs.
Leveraging Joy’s reliability-centered maintenance (RCM) framework with GE Digital’s APM solutions and implementing strategy management capability allowed the operators to prioritize the required maintenance, move maintenance recommendations directly into the RCM module, and create strategy templates based on these recommendations. Reviewing of these templates before being tailored for specific requests after gaining approval from service management and maintenance divisions not only helped the Joy team conduct quality checks of risk evaluation, action definition, and costs, but also ensured the company processes are in compliance with the IPSECA requirements.
Benefits: Joy’s selection of GE Digital’s APM offerings proved to be a step in the right direction, with the solution helping the company optimize maintenance strategies and reduce processing time by about 75 percent. This in turn resulted in improved asset availability and reduced production losses, operational risks, and overall business costs. The solution also aided the company to perform continuous improvement analysis using APM and work histories from SAP. Analyzing the process history before implementing the solution was deemed difficult, if not impossible.
Keywords: Asset Performance Management, GE Digital APM Solutions, Joy Global, ARC Advisory Group.