Background

MSD (Avondale), formerly Schering Plough, is a pharmaceutical API manufacturing plant.  MSD use IBM Maximo as part of their Maintenance Management Process. As MSD is regulated by the IMB and FDA, Maximo is a validated system.

IBM Maximo printed work orders and any attached Maintenance Work Instructions  (MWI) for all Preventative Maintenance (PM) and Corrective Maintenance (CM) work orders. The completed signed work orders were retained as the record of note. This involved scanning and verifying the work orders to their document management system (Zyimage).

The challenge was to remove the dependency on scanned paper records. 

Solution

System Dynamics undertook the requirements, design, development and testing phases, followed by extensive validation testing.  This consisted of an installation verification for configuration changes and a functional verification for the new processes including screens, reports and document attachments. 

New training modules were developed for all users. By extending the use of Maximo, all users now interact directly with the electronic work order.

Craft Coordinators:

• Used a new report to assign Craft(s) to the work order and to inform the Craft(s) of the work orders assigned.
• Reviewed the electronic work order.
• Updated details directly to the electronic work order.
•  Reviewed completed work orders and added additional comments if necessary.

Benefits

The implementation has provided the following benefits:

• Maximo became the record of note for work orders carried out by the maintenance department, replacing Zyimage.
•  All relevant information including labour and materials are recorded directly to Maximo. 
• Where MWIs need to be printed and annotated, the printing is controlled and the documents are attached directly to the relevant work order.
• Removal of printing of work orders and MWIs provided a direct cost-saving.
• Users interact directly with the work order. Maximo controls the information entered to ensure that it is valid and accurate.
• Administrative staff no longer need to scan all completed work orders.