A global life sciences manufacturer operating in more than 100 countries was struggling with reliability issues at one of its largest plants.
The company needed to create or update existing bills of materials (BOM) for all equipment, including sub-components, while establishing parent/child relationships. A review showed that BOMs were incomplete, identification structures housed in the company’s system of record were inconsistent, and spare parts were not tied to specific equipment.
The situation created a risk for equipment failure as well as compliance with the Food & Drug Administration (FDA) regulations governing the facility. Both could have disastrous effects on production and profitability.
All BOM projects have challenges. Data often plays a significant role in causing and solving problems.
In this case, the client was unsure what equipment changes were made over the years. There was little confidence in the available technical data, thus requiring walk-downs, where parts were identified in person. The initial project contractor completed a physical walk down on the 22,000 assets identified during the project, eventually sharing the information collected. But that information was lacking in data consistency, as well as the depth of information collected. Much of it had to be redone.