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An On Key EAM implementation that unlocked efficiency and optimised operations

Cooper/T. Smith de México, a prominent player in the Mexican Port of Altamira, faced asset management challenges that hindered their operations. Our intervention revolutionised their approach, resulting in substantial improvements, including increased equipment availability, reduced maintenance costs and enhanced overall productivity.

“Pragma exceeded our expectations, and to our great satisfaction, this project surpassed its goals and represented an economic benefit of an ROI of 9.4 to 1.”
– Arturo Encinas Valenzuela, Executive Director –

Key challenges

The client’s limited asset management maturity resulted in inefficiencies and higher operational costs. Maintenance processes were reactive leading to increased downtime, higher maintenance costs, and lower equipment availability. The lack of a structured AM approach posed significant challenges due to the need to process bulk cargo in a timely and cost-efficient manner.
Penalties and delays due to equipment breakdowns, maintenance being delayed, and unoptimised maintenance strategies were having a negative impact on profitability as well as reputation.
There was no asset criticality plan in place for critical assets, resulting in some critical assets not receiving the necessary attention, and less critical ones being over-maintained.
A lack of effective performance monitoring tools and key performance indicators (KPIs) for tracking and analysing operations made for difficult data-driven and informed decision-making.

Our intervention

Before the project was launched, an AMIP (Asset Management Improvement Planning) assessment gave insight into and understanding of the client’s AM maturity. The results were benchmarked against international and local companies, and a clear action plan was developed based on the results.
The AM objectives, policy and strategy were defined in a series of strategic workshops facilitated by the project’s executive team.
The project’s first phase was successfully implementing the On Key EAM (enterprise asset management) system. On Key EAM enabled the implementation of the asset management objectives in line with the planned sustainable asset management journey.
Customised Work Planning and Control processes were developed and implemented to facilitate tactical maintenance management throughout asset lifecycle phases.
An asset criticality matrix was developed to apply specific maintenance strategies for critical assets.
An OMM (optimum maintenance mix) process was implemented to analyse the current reactive maintenance state to one of reliability-centred maintenance where maintenance plans could be optimised.
A series of dashboards and KPIs were developed using On Key Insights, our BI platform, to control and analyse performance levels.

Value add

Equipment availability increased by 26.6%
Maintenance costs were reduced by 25.8%
Penalties paid due to delays were reduced by 17.2%
Overall productivity increased by 15.8%
The project’s economic benefits represented a return on investment of 9.4 to 1

Client background

Cooper/T. Smith de México has operated and managed the specialised public terminal for handling mineral bulk and general cargo in the Mexican Port of Altamira, Tamaulipas, for over ten years.
The public terminal has a 600m waterfront and a 22 ha storage area. The terminal has two docks, allowing for the berthing of ships up to 260m long and 32.20m beam. They can receive up to 80,000 deadweight tons (dwt) ships. There is an unloading/loading capacity of between 14,000 to 20,000 tons per day for bulk materials, depending on the type of ship and the density of the material.
The terminal and its storage yards are authorised to operate as a controlled area, which gives port customers competitive advantages in foreign trade and provides cargo security due to the controlled access to the entire terminal and closed circuit television.

Luxury resort in Macau, China makes the switch to On Key EAM

Dive into the transformation ignited by On Key at two illustrious, five-star havens in China. Confronted with the mammoth task of curating an unparalleled guest experience and managing a large contingent of maintenance and housekeeping staff, the client hungered for streamlined workflows, turbocharged efficiency and unwavering compliance. The transition unfurled seamlessly through tailored On Key EAM configurations, translating its interface into Chinese and orchestrating integrated solutions.

“With On Key’s enhanced functionality and configuration attributes, we have elevated our ability to deliver on our brand promise. Running a top-tier maintenance operation, On Key helps us enhance the guest experience, ensuring our guests enjoy a truly exceptional stay at our resorts.”
– Ignus Zietsman, On Key Business Area Manager –

Key challenges

As two prestigious five-star luxury resorts in China, delivering an exceptional guest experience is paramount for this client. However, effectively managing a large workforce of maintenance and housekeeping staff, coordinating communication, tracking work requirements, and utilising data proved to be a significant challenge and administrative burden.

To address these challenges, the client sought a maintenance management system partner who could understand their unique needs, configure a system aligned with their brand promise, streamline facilities management workflows, boost efficiency, and ensure compliance.

During the transition from Maximo to On Key EAM, the dedicated On Key team focused on deploying seamless integration solutions and facilitating staff adoption through effective change management processes.

Our intervention

Customised configuration of On Key EAM to match client requirements, including operations roles, user profiles, and dashboards.
Full translation of On Key EAM’s front end and its applications to Chinese.
Configuration of On Key EAM and its applications to match the client’s business processes.
Launched a train-the-trainer programme for effective knowledge transfer.
Customisation and deployment of the On Key Work Portal and Field Engineering application.
Deployment of On Key Insights, our business intelligence (BI) platform and end-user training.
Development of integration solutions to enhance efficiency.
Configuration of Zabbix, an enterprise-class open-source solution, for server health monitoring, early detection of performance issues and automatic IT notifications.

Value add

The client now enjoys an integrated, paperless maintenance operation with streamlined workflows, enhanced efficiency, improved accuracy and reduced costs for managing maintenance processes.
Established a centralised electronic asset register for more efficient physical asset management, accurate tracking, improved financial management, enhanced security, compliance and streamlined collaboration within an organisation.
All unplanned or reactive maintenance and housekeeping-related work orders (system generated and work identified by housekeeping staff) are automatically allocated to relevant resources based on availability.
Enabled maintenance and housekeeping resources to provide realtime feedback conveniently through the On Key Field Engineering app, ensuring accurate and relevant information for enhanced data accuracy.
Implemented a comprehensive business intelligence reporting platform, On Key Insights, to analyse and visualise data, gain valuable insights, make data-driven decisions and improve the maintenance function’s overall performance.
All planning processes are automated, streamlining the entire maintenance and housekeeping function and freeing up personnel for other work.
Accessing On Key’s front end and applications in Chinese facilitates effective communication, understanding and utilisation of the system.

Client background

Our client owns two luxurious hotel and casino resorts in Macau, China. They offer 2,716 elegant rooms, suites, villas and a vast casino space measuring 62,800m2. Additionally, there are 28 dining options, 6,300m2 of meeting and convention facilities, 15,000m2 of designer retail space, spas, salons, a remarkable art collection and other attractions.

The client boasts a large in-house maintenance team comprising 2,000 engineers, technicians and housekeeping staff. Impressed by the enhanced functionality and configurability, the client transitioned from a an industry-established maintenance management system they had used for several years to On Key.

On Key enables Pragma's Generator Asset Health Management.

From vision to reality: A game-changing impact on Pragma’s Asset Health Management for generators

Discover how the On Key team revolutionised Pragma’s Asset Health Management for generators using On Key EAM and IIoT technologies in this case study. Realtime data, smart asset care plans and automated work orders lead to improved business sustainability and significant cost savings.

“The On Key team and solution contributed tremendously to shaping the vision of an Asset Health Management service into a tangible reality. They integrated with the project team and, through close collaboration, fully understood the task at hand and delivered exceptional results.”

Morne Steenkamp – Manager: Pragma Asset Health Services

Key challenges

The team intends to monitor hundreds of generators from a single control room. If smart technologies aren’t used, this becomes a significant operational and asset health risk mitigation challenge. The volume of assets that will be monitored and managed by the team makes it difficult to manually trigger maintenance actions based on the health status of a generator.

Each generator’s asset care plan (ACP) must be centrally maintained and updates synchronised to all generator instances.

Contractors need to be managed and controlled effectively.

Work management needs to be effective and efficient, and work feedback must be accurate and immediately available for analysis.

The business unit must guarantee asset reliability and availability of its clients’ critical assets.

Our intervention

On Key provided the entire IIoT technology stack, including the hardware, visualisation platform, external database integration, and EAMS capability.
A trained contractor installed the hardware to collect data from Deep Sea-type generator controllers. The On Key team supported this by testing and commissioning the solution.
Dashboards were developed to visualise and present the generators’ realtime data.
The On Key team assisted the client in developing a template-based comprehensive ACP for generators to manage and maintain centrally and easily deployed to hundreds of sites. The ACP also includes technology-driven tasks, such as monitoring point entities that capture realtime data, trigger alarms, and create work orders.
An automatic export service was created to export specific realtime data to an external SQL database for analytics purposes.

Value add

Asset availability
Prioritise risk management
Effective fuel management
Improved business sustainability
Efficient and effective maintenance enabled by comprehensive and smart asset care plans
Cost savings as a result of contractor invoice validation
Better decision-making made possible through realtime data and business intelligence
Reduced human error
Automated work identification enabled by IIoT technology and EAMS integration
A digital twin is established from a combination of data sources and tools such as IIoT dashboards and hardware, failure history and maintenance costs captured by an EAMS

Client background

The Asset Health Services business unit within Pragma delivers asset-type specific health management solutions for business-critical assets.
A dedicated team of specialist engineers help their clients to optimise asset health through the implementation of the necessary predictive asset management business processes aided by using smart technologies, such as IIoT.
The initial implementation was on a regional-wide backup power generator implementation. The plan is to expand the offering into other crucial asset types.

Case Study | Tetra Pak® Packaging Solutions | 158% Increase in Maintenance Plans Updates using On Key EAM

“Pragma, with its expertise and technology in asset and maintenance management, is a key strategic partner for Tetra Pak® Maintenance Services. We have built a strong partnership with them over many years and value their input on a day-to-day basis.
Peter Sundin, Manager Maintenance Management, Tetra Pak® Technical Service

Key challenges

The food processing and packaging industry is constantly pressured to reduce costs and increase productivity. Tetra Pak® has been the industry leader for many decades and needs to continually adapt to remain in this position.

As a company that operates in more than 170 countries, global operational challenges are plentiful:

Different languages and cultures in regional offices and customers.
Unique operating conditions.
Field service work execution in all markets
Diverse skill levels of engineers, contractors and customers.
Growing equipment platforms installed base and increase in technological complexity.

Accurate information management has become mandatory for successful service delivery.

Our intervention

Tetra Pak® chose the On Key EAM system as the primary business application for its Maintenance Management operations.

The Pragma project team: led the design of the system configuration and data population process; participated in the Asset Care business processes that form part of the Maintenance Process; supported the global deployment of the system; facilitated the integration of the On Key system with the Tetra Pak® SAP® ERP system.

The Pragma Asset Care Centre team provides ongoing support globally in the: maintenance recommendation development;
asset register administration and asset initialisation; preventive maintenance event generation; quality assurance of work order
feedback; general support to the maintenance management functions in all the regional Tetra Pak® offices.

Value add

Globally supported Asset Care Centre.
Standard processes applied consistently across different conditions.
Accurate, up-to-date and reliable information.
Single repository of all service work.
Streamlined process to manage.
Support Tetra Pak® Maintenance Services:
- to support full line maintenance contracts;
- to reduce maintenance cost on the installed base;
- to increase OEE on equipment.
On Key is the enabler:
- to do accurate maintenance cost calculations;
- to manage service contracts;
- to improve MR’s based on feedback;
- to customise and optimise schedules and MR’s per machine.

Client background

Tetra Pak® is the world’s leading food processing and packaging solutions company. Working closely with their customers and suppliers, they provide safe, innovative and environmentally sound products that, each day, meet the needs of hundreds of millions of people in more than 170 countries around the world. With over 23,000 employees based in over 85 countries, Tetra Pak® believes in responsible industry leadership and a sustainable approach to business.

Tetra Pak® Services cover every aspect of a customer’s food production, from daily routines to business insights. The tailored service solutions improve performance, optimise costs and ensure food safety throughout the lifecycle of a customer’s operation. Partnering with Tetra Pak® gives their customers the people, portfolio and presence to achieve their performance goals.