AVEVA's Maintenance managemen solution pays off for CF industrial fertilizer plant
CF Industries, Inc. is one of the largest manufacturers and distributors of nitrogen and phosphate fertilizer products in North America. Its operations are organized into two business segments: the nitrogen fertilizer business and the phosphate fertilizer business. The main products in the nitrogen fertilizer business are ammonia, urea and urea ammonium nitrate solution, or UAN. The main products of the phosphate fertilizer business are diammonium phosphate (DAP) and monoammonium phosphate (MAP).
Locate and implement a new solution.
CF Industries set out to find software that offered the maintenance planning functionality they had been enjoying in the IBM environment while also providing the flexibility they needed to grow. They located the necessary software in AVEVA Enterprise Asset Management, an asset performance management (APM) solution.
Goals
- Deliver continuous and automated maintenance planning functionality.
- Improve on the current structured maintenance system to reduce the risks associated with unforeseen equipment failures.
- Provide the flexibility for growth and cost savings.
Challenges
- To drive down operating costs - the investment to keep homegrown application in pace with growing business was expensive (well over $1 million).
- The need to boost efficiencies – analyzing data for asset monitoring took too long.
Solutions
- AVEVA Enterprise Asset Management (APM)
Results
- Reduction in operating costs by up to 10%, through improved operations and automation.
- Potential revenue improvement of up to 5% .
- Time to analyze asset monitoring data reduced from two weeks to ten minutes, through successful integration with multiple systems and consolidation of visualization dashboards and KPIs, resulting in a streamlined business workflow.
- Full ROI achieved rapidly and continues to grow - the solution has paid for itself many times over.
“We can now ensure that maintenance materials and services are there when we need them, know what it costs to maintain the plant, and know the best way to maintain it based on history. This puts us way ahead of the game.”
Dave Wiedenfeld, Group Project Leader, IT, CF Industries