Toyota UK began using IBM Maximo as its EAM system in 2004, to standardizeproduction maintenance processes and improve effectiveness whilst reducingcosts. Although successful, a level of manual intervention and subjectivityinevitably remained within maintenance processes.
When a fault occurred, SCADA monitoring would visually display an alert. Thecontrol room operator then nominated a maintenance engineer working on theshop floor to immediately leave their work area and attend to the alert. After theinspection, the engineer would return to a PC and input relevant maintenance datamanually into Maximo.
This way of working resulted in inefficiencies and it was clear there were
opportunities to further improve. Toyota UK began exploring how mobile devices
could be used within maintenance operations because management believed
mobile working would result in further operational improvements, widen access to
maintenance information and help to cut costs.
Linking SCADA with Maintenance
After a market evaluation, Toyota UK made the decision to implement EXTEND7000
from SCHAD. As a mobile SCADA and maintenance solution, EXTEND7000 stood
out because it offered a unique ability to connect SCADA controlled automation
systems to the Maximo driven maintenance system. Of particular interest to Toyota
UK was EXTEND7000s ability to link directly to the factorys main SCADA systems
and pick up asset data directly from the PLC.
Toyota UK also wanted to gather detailed information about asset breakdowns. For
instance, recording why a failure occurred, the spare parts used, time to fix and
total downtime, which is essential for gaining a deeper understanding of
After implementing EXTEND7000, Toyota UK saw an improvement tomaintenance efficiency. In addition, the need for a dedicated operator per shift tomonitor SCADA alarms and control the maintenance process was removed.Instead, PLCs sent maintenance alarms directly to engineering teams, with relevantdata transferred into Maximo at the same time. This has helped to achieve hugecost savings and also removed the subjectivity of having an operator make on thespot maintenance decisions. Associated data related to an asset fix is retained andflows straight into Maximo, to enable greater analysis of general machine healthand condition.
Better Communication and Workflow
All personnel involved with assembly line maintenance now use EXTEND7000 on
every shift. Based on a traffic light warning system, alerts are open to any team
member and once accepted, an alert is assigned to a named individual. This
ensures that all members are aware of the status of active issues and can respond
quickly. Each alert then remains in the system until the relevant PLC machine
notifies the central server that the asset is working as normal again, at which point
it is deleted. The benefit of using EXTEND7000 is that at all times, the whole team is
fully informed of all maintenance activities and if an alert is not responded to, a
follow up alert is triggered to explore why no one has accepted it.
Toyota UKs maintenance operations have benefited in many other ways from
using EXTEND7000. The dead time incurred by engineers walking between jobs
has been cut, which means more maintenance tasks can be completed each day.
Workflow management has also improved and team members have a mobile jobs
list showing a clear outline of work assigned plus their ongoing workloads.
In-between attending to breakdown calls, team members can pick up another
planned task or attend to alarms.
Improved Preventative Maintenance Performance
As well as boosting maintenance efficiency, the time required for processing
information about completed jobs has reduced. In addition, the overall quality of
data captured has improved, which in turn improves preventative maintenance
performance. This is based on maintenance engineers working across all
maintenance shifts and represents a reduction to annual labour costs. Significantly,
no adverse effect to shop floor OPR was reported during the implementation
process and maintenance operations were able to continue as usual.
Having seen how EXTEND7000 can benefit Toyota UKs assembly line maintenance,
use of the system is being extended to other areas. In addition, EXTEND7000 will
start to manage significant planned maintenance tasks supported by additional
documentation, for instance drawings, instructions or wiring diagrams, which are
sent to the mobile device with each work order.
Training is another area that will be driven by EXTEND7000 in the future. Using
EXTEND7000, training based work orders will be sent to each device directly,
allowing individual members to manage their own training programmes.
Spares ordering will also be completed through EXTEND7000, with orders and
replenishment requests sent directly from the mobile devices. Ordering spares
using EXTEND7000 represents a very important improvement because it means
maintenance workers dont have to leave their work areas, saving a huge amount
Full ROI in Six Months
Reflecting on the success of the project as a whole, Toyota UK has measured a full
return on the investment made in EXTEND7000 within six months, through a wide
range of cost savings and efficiency improvements. The initiative was well received
by the maintenance teams and all involved appreciate the operational benefits of
greater mobility. Now, Toyota UK is planning to mirror these achievements in other
maintenance divisions, starting imminently with plastics.