BP’s industrial lubricants keep vehicles, equipment and machinery running. The Mönchengladbach plant produces special oils and fats for industrial applications. Many products marketed in this area under the Castrol brand are adapted to the wishes of numerous industrial customers.

The task
For the Mönchengladbach site, we have implemented Asset Portfolio Management and a multi-year investment plan. The following aspects had to be considered:
– New products including certification of the production process (quality assurance, permission from the customer to modify processes)
– Expansion and flexibilization of current production capacity
– Replacement projects required due to end of life
– Meeting stricter environmental requirements (re-use of process water)
– Stricter internal safety requirements (additional fire safety provisions)

The Approach
Although the local focus was on growth projects, we discovered that the absence of a structural asset portfolio analysis and recent inspection results (asset condition) meant that for two critical utilities other priorities had to be set in the investment portfolio, to guarantee the continuity of the production.

Mainnovation’s added value
Together with the customer, we created and implemented an asset portfolio for the Mönchengladbach site for the next 3 to 5 years, resulting in:
– Insight into the growth and replacement projects for the next 3 years
– Timely completion of replacement projects avoiding risk of production outage
– Introduction of project definition phase (scoping) has led to better forecasting and cost control
– Good planning and continuous coordination with production, has led to a minimization of production outage during the realization phase
– Better predictability of the time to market for new products

more cases

  • Potential risk reduction of 58% was achieved for the first 3 production plants.

  • Maintaining the high operational reliability of the new installations is a top priority

  • ‘Expert Driven Implementation’ method