Maintenance Technology June 2017 - 10

PLANT PROFILE

AZ Puts

Proactive in

RELIABILITY
Biopharmaceutical
manufacturing
company
AstraZeneca
redefines reliability
to streamline
more-effective
maintenance
processes.

Michelle Segrest
Contributing Editor
10 |

MAINTENANCE TECHNOLOGY

EVEN THOUGH THE AstraZeneca
manufacturing facility in Mt. Vernon,
IN, looks like a hospital surgical
unit-with key equipment separated into
concentrated clean rooms-for years it
operated like an emergency room. When
an equipment breakdown occurred,
personnel jumped into action, triaging the
issue and not always looking into the true
symptoms to prevent future occurrences.
The company acquired the Mt. Vernon
facility in August 2015. With a new
reliability unit in place and an Operations
Excellence Team, the site now has teams
focused on preventing emergencies,
instead of addressing them.
Reliability and maintenance can be
a challenge when maintaining a high
standard for the pharmaceutical environment. As you walk through the facility, the
white walls and floors glisten against the
shiny, almost mirror-like, stainless-steel
equipment. Equipment and personnel
rooms serve as airlocks between the
corridors and the manufacturing rooms.
The airlocks are guards against dust,
dander, allergens, or other elements that
could contaminate the critical medicine
that is being manufactured. The switch
from a reactive to a proactive, risk-based,

approach has taken reliability in the
700,000-sq.-ft. manufacturing area to a
new level.
"Our first step was to separate our
reliability team from the day-to-day
commotion," explained facilities engineer
Andrew Carpenter. "We had to be sure
they understood that reliability is different
than maintenance, and we had to all take
this seriously. We had many people who
were specialists and were relied upon for
troubleshooting and fixing emergency
issues. It was a complete mindset change."
The new reliability team received
support from upper management and
buy-in from the team. Although some
roles changed, the team remained
headcount neutral. This, along with clear
alignment of goals, became the keys to a
successful transition.
"If you are starting a reliability program
in your plant, call it what it is," senior
building and reliability manager Chris
Nolan said. "Reliability is different than
maintenance. The goal is to get to a certain
utopia. As your group grows, you all
become more focused on that reliability
side, but when you are starting out with a
reactive-maintenance program, and you
want to transition to one that is reliability
JUNE 2017



Table of Contents for the Digital Edition of Maintenance Technology June 2017

Editorial
Uptime
On The Floor
IIoT
ISO 55000
Products
Ad Index
Showcase
Final Thought
AZ Puts Proactive in Reliability
Glimpse The Future of Predictive Maintenance
Automation-System Updates
MRO: Counterfeit Parts
MRO: Reduce Your Lube Inventory
MRO: Optimize Belt Conveyor Systems
Manage Used and Waste Oils Wisely
Motor Insulation Test Payback
SAP: Tips and Tricks
Cool Off Compressors
Be A Safety Leader
Maintenance Technology June 2017 - Cover1
Maintenance Technology June 2017 - Cover2
Maintenance Technology June 2017 - 1
Maintenance Technology June 2017 - 2
Maintenance Technology June 2017 - 3
Maintenance Technology June 2017 - Editorial
Maintenance Technology June 2017 - 5
Maintenance Technology June 2017 - Uptime
Maintenance Technology June 2017 - 7
Maintenance Technology June 2017 - On The Floor
Maintenance Technology June 2017 - 9
Maintenance Technology June 2017 - AZ Puts Proactive in Reliability
Maintenance Technology June 2017 - 11
Maintenance Technology June 2017 - 12
Maintenance Technology June 2017 - 13
Maintenance Technology June 2017 - Glimpse The Future of Predictive Maintenance
Maintenance Technology June 2017 - 15
Maintenance Technology June 2017 - 16
Maintenance Technology June 2017 - 17
Maintenance Technology June 2017 - Automation-System Updates
Maintenance Technology June 2017 - 19
Maintenance Technology June 2017 - 20
Maintenance Technology June 2017 - 21
Maintenance Technology June 2017 - MRO: Counterfeit Parts
Maintenance Technology June 2017 - 23
Maintenance Technology June 2017 - 24
Maintenance Technology June 2017 - MRO: Reduce Your Lube Inventory
Maintenance Technology June 2017 - 26
Maintenance Technology June 2017 - 27
Maintenance Technology June 2017 - MRO: Optimize Belt Conveyor Systems
Maintenance Technology June 2017 - 29
Maintenance Technology June 2017 - 30
Maintenance Technology June 2017 - 31
Maintenance Technology June 2017 - SAP: Tips and Tricks
Maintenance Technology June 2017 - Cool Off Compressors
Maintenance Technology June 2017 - Be A Safety Leader
Maintenance Technology June 2017 - 35
Maintenance Technology June 2017 - IIoT
Maintenance Technology June 2017 - ISO 55000
Maintenance Technology June 2017 - Manage Used and Waste Oils Wisely
Maintenance Technology June 2017 - 39
Maintenance Technology June 2017 - 40
Maintenance Technology June 2017 - Motor Insulation Test Payback
Maintenance Technology June 2017 - 42
Maintenance Technology June 2017 - Products
Maintenance Technology June 2017 - 44
Maintenance Technology June 2017 - 45
Maintenance Technology June 2017 - Ad Index
Maintenance Technology June 2017 - Showcase
Maintenance Technology June 2017 - Final Thought
Maintenance Technology June 2017 - Cover3
Maintenance Technology June 2017 - Cover4
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