Product category:
Asset Management and maintenance planning
News Release from: AV Technology | Subject: CTB Chirk assets
Edited by the Processingtalk Editorial
Team on 02 April 2007
Asset maintenance programme for Cadbury
AVT is playing a crucial role in keeping equipment at the Cadbury Trebor Bassett cocoa bean processing plant at Chirk in tip-top condition, helping the company achieve interruption-free production
An outsourced asset maintenance programme from Stockport based AV Technology is playing a crucial role in keeping equipment at the Cadbury Trebor Bassett (CTB) raw material processing plant at Chirk in tip-top condition, thereby helping the company achieve interruption-free production The Chirk plant is responsible for processing imported raw cocoa beans into butters and fine liquor extracts, which are then supplied to other Cadbury plants to be turned into Cadbury Dairy Milk products
This article was originally published on Processingtalk on 29 Jul 2003 at 8.00am (UK)
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The process also produces a powder by-product which is granulated, sweetened with sugar and turned into drinking chocolate at the Chirk site.
The humble cocoa bean, which provides the main ingredient for a bar of chocolate or a tasty cup of cocoa, requires extensive processing before it can be used and, like many primary processing plants, the main production area at Chirk is harsh and noisy, with temperatures well above ambient in some sectors.
The process begins with the raw bean, which is sorted to remove heavy and light foreign bodies and then heat treated to kill any bugs or bacteria.
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The bean is then roasted, after which bean, shell and nib are separated.
The shell goes off to be used in farm feed, while the nib is processed into finished liquor for distribution to Cadbury sites at Bourneville and Hereford.
The expellers and butter extract are processed into finished cocoa butter, also for distribution, while the powder residue goes through a preparation process to produce drinking chocolate.
The key to maintaining production rates at the Chirk raw materials plant is to keep a 'watchful eye' over the conditions of machines and take preventative action to avoid unplanned shutdowns, and keep production running at optimum levels.
As a result effective asset maintenance is crucial.
Of course, a 'watchful eye' involves much more than just a visual inspection of a machine, and as it is vital that the plant runs 24 hours a day, seven days a week without interruption, CTB takes the issue of asset management very seriously.
With the site split into 21 routes, and 744 machines involved in the process, Cadbury needed an integrated maintenance solution which could not only monitor assets to ensure they are working properly, but would also offer the opportunity to make productivity improvements.
The latter benefit is important to the Chirk site, since it is competing with other Cadbury raw material production plants within the EMEA (Europe, the Middle East and Africa) region, including areas where labour costs are much lower.
Increasing productivity helps ensure the site remains competitive.
AVT has taken total responsibility for asset maintenance at the Chirk plant and uses a number of maintenance techniques to meet the CTB requirements.
AVT have permanent staff deployed at the Chirk site, who work closely with the CTB engineering management.
Currently, the two most important maintenance techniques carried out at the site are lubrication management and equipment condition monitoring.
The strategic maintenance support improvement planning programme is divided into phases, with the first phase being a health check of the machines on site.
This identifies Areas for Improvement (AFIs) against benchmarks and attainable goals.
These AFIs are prioritised against value and ease of implementation.
The second blueprint phase involves the full implementation design of the AFI solution programme.
Phase three is when the implementation takes place along with on-going support and hands-on guidance as necessary from AVT.
Maintenance support services include the identification (each piece of equipment covered by the contract is fitted with a bar code label to facilitate electronic record keeping), quality check and input of assets onto the Cadbury CMMS (Computerised Maintenance Management System).
This system is integral to the effectiveness of the maintenance programme, and AVT have made improvements to the system to enhance its capabilities.
The Total Lubrication Management programme involves product procurement and stock management; advice on the correct lubricant for the application, which reduces costs by prolonging life between lubrication changes; advice on lubrication requirements, replacement and improvements; a standalone CMMS which takes an holistic approach to control lubrication tasks; machine signalisation for ease of maintenance and identification to avoid cross-contamination; reports produced in the form of fault reporting; and high oil consumption or leakage.
For example if any of the gearboxes are leaking, the problem first needs to be identified, followed by understanding the cause and then providing the solution.
AVT Senior Engineer David Stevens is keen to dispel the myths that maintenance engineers are seen as oilers and greasers.
Equipment does need regular lubrication but as he explains: "Our involvement goes much further than walking around with an oily rag, oil can and grease gun! Lubrication is a science all of its own and the selection of the correct lubricant is as important as the lubrication process itself".
The management system also includes waste oil collection and storage for environmental control purposes.
This programme helps to maintain lubrication quality, which in turn, means maintenance costs are reduced.
Equipment condition monitoring at the Chirk site employs three techniques, vibration analysis, thermography and oil sampling.
Vibration analysis is carried out monthly, and is based on criticality, with 145 machines and over 1200 measurement points included in the database.
All historical trend and spectral data is retained for analysis, diagnosis and prognosis.
This data is collected and analysed on a monthly basis and when required additional supporting data can be collected on an ad-hoc basis.
Monthly reports are issued, but if the information is time critical, specific reports can be issued, which give details of faults and recommended actions.
Thermography is used to survey the site electrical panels and switch gear on a bi-annual basis.
This technique can identify small irregular heat sources or hot spots, well in advance of any problems.
An in-depth report is then issued which highlights any faults, with photographic evidence for ease of identification.
The third aspect, oil sampling, can be used as either a primary or correlation technique and monitors both the condition of the oil and machine.
It is carried out on a quarterly and six monthly basis, or whenever required if necessary.
A full report gives information on the lubricant condition, including viscosity, TAN (Total Acid Number), water content, as well as spectrometry, which gives details about machine wear and damage.
Effective asset management is about identifying potential problems or areas of failure within a machine and then taking steps to eliminate the problem before it causes a process interruption or plant shutdown.
As David Stevens concludes: "More and more companies are seeing the advantages of outsourcing these vital services and by working in partnership with experts in this field such as AVT, they can benefit from our extensive practical factory floor experience, together with our valuable external technical resources and testing capabilities.
We also offer a host of other asset maintenance and management techniques, which hopefully CTB will take advantage of in the future". Request a free brochure from AV Technology ...
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