Remondis Sava GmbH operates one of the most modern hazardous waste incineration plants in Europe in Brunsbüttel. Due to the hazardous nature of the material, the plant is under strict observation by the authorities. This means that special requirements regarding risk precautions, safety plans and the various maintenance tasks must be adhered to and fully documented. Maintenance management was previously characterized by many manual processes that were both time-consuming and error-prone. Remondis therefore set itself the goal of automating and optimizing maintenance. This was achieved with the help of the know-how of handz.on’s IT experts and a new version of IBM Maximo’s Enterprise Asset Management (EAM) solution already in use at the company.
The various maintenance tasks that need to be carried out in the waste incineration plant include checking seals, scheduled checks of pressure vessels and pumps and changing fluids and filters.
“Previously, we had to check the maintenance program once a week to see what work was currently due and then trigger it manually at the touch of a button,” recalls Stefan Homfeldt, Head of Maintenance and Repair at Remondis Sava. “Of course, it sometimes happened that something was forgotten.” The new Maximo solution, which was customized by handz.on, now automatically checks which maintenance work is due and triggers it.
In general, everything that is subject to inspection is stored in the solution – including all activities that the respective maintenance involves. “From fans to larger units, pumps, deslaggers, pressure vessels, but also cleaning schedules – everything that needs to be checked on a recurring basis,” says Homfeldt. The maintenance module not only automatically schedules the specified intervals, but also creates the resulting work orders.
The web-based solution also manages unexpected defects and the purchase of spare parts required for maintenance. These are automatically reserved and reordered if they are not in stock. The software also has a status management function that allows authorized employees to obtain detailed information about the status quo at any time. Thanks to the web-based approach, the solution works on any computer.
The system also provides the documentation that is so important for Remondis as proof that the statutory regulations are being complied with. In the event of an audit, for example, all orders and the complete life cycle management of the system and its components – from procurement to repairs to scrapping – can still be retrieved after ten years, even if the components in question no longer exist.
When asked what else he would like from handz.on and the solution, Stefan Homfeldt replies: “A better print function. The current solution in Maximo is such that it feels like we have to click ten times before a document is printed – we’ll work on that with handz.on.”
Another advantage of the solution is the detailed evaluation of maintenance costs, as all data on employee deployment, spare parts and financial expenditure is stored in the system. “We can create reports as required and see exactly what the system costs and how we can further increase its efficiency,” explains Homfeldt
The cleverly programmed, fully automated maintenance processes of the Maximo solution ensure that error-prone manual processes are eliminated and the entire system is optimally maintained at all times. This minimizes the risk of consequential damage and breakdowns due to incorrect or non-executed maintenance. This not only makes it easy to comply with legal requirements, but also avoids additional costs and increases efficiency.
As Remondis uses the Maximo solution to map the entire EAM (Enterprise Asset Management) – for example, order processing, asset inspection, ordering, warehousing, procurement and cost evaluation – no interfaces to other systems are required. The company therefore benefits from a standardized system and the end-to-end service provided by handz.on from a single source. This also includes training for the Remondis employees responsible for the maintenance system. “We learn how to customize the workflow of the system and the integrated tools ourselves and can therefore save costs,” explains Homfeldt.
With so many benefits from the solution and management provided by the handz.on team, it is no surprise that Remondis wants to continue and expand the collaboration in the future. The next step planned is the introduction of the Maximo Scheduler. This should ensure that resources can be allocated and scheduled even better in the future.
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