Manola MaintenanceSpecialty polymer manufacturer, California
The problem
The site's SAP hierarchy no longer matched the plant, and many PMs were generic checks that could not be traced to a failure they were meant to prevent.
What we did
We walked down the plant and rebuilt the functional location and equipment hierarchy, then reconciled it against the live SAP data after upload. Every row was accounted for, including superior equipment links for nested items.
On one production line we ran an FMECA using the client's own scoring rubric, matched each failure mode to the PM that covered it, and rescored detection where the existing PM could not in fact detect the failure. Seven clarifications to the rubric were written up and accepted by the client.
The gap analysis then drove a rebuild of the line's PMs: procedures written against named failure modes, with isolation points, measurable acceptance criteria and site photographs. Calibration stayed with the site's existing calibration group.
Results
- Every upload row accounted for when the hierarchy was reconciled against live SAP data
- Each failure mode on the line matched to the PM that covers it, or flagged as a gap
- Open actions cut after detection was rescored against the evidence
- New failure-mode PMs for the line, with isolation points and acceptance criteria