On the way to World Class Maintenance with BMC ®

The modular approach to maintenanceMartin Scheitler

Bilfinger Maintenance GmbH

ACHEMA 2015, Frankfurt am Main | 15 -19 June 2015

▪ Bilfinger Maintenance GmbH combinesthe former companies:

▪ Maintenance Südwest GmbH, Leimen

▪ Maintenance Nord GmbH, Leuna

▪ Maintenance Nord EMV GmbH, Neuss

▪ Maintenance Süd, Frankfurt

▪ With 30 branches and more than 2,200 employees, the company is the largest maintenance services provider in Germany.

▪ ... is specialized in maintenance and plant engineering for industrial facilities.

▪ ... is one of a very small number of providerson the market able to offer clients servicesfor the entire lifecycle of their industrial assets.

▪ ... its services portfolio covers plant engineering through to maintenance and turnarounds, modifications and expansions as well as demolition and conversion.

Bilfinger Maintenance GmbH

INCREASED NETWORKINGCUSTOMER & SERVICE PROVIDERDEMAND IMPROVED COMMUNICATION

NEW BUSINESS MODELS

INCREASINGSYSTEM COMPLEXITY

DEMOGRAPHIC CHANGE

TECHNOLOGICAL DEVELOPMENT- AUTOMATION- INDUSTRY 4.0- MOBILE APPLICATIONS

POTENTIAL IN PRODUCTION AND SERVICE LARGELY DRIED UP

FURTHER OPTIMIZATION REQUIRES INCREASED NETWORKING

SHORTER MARKET CYCLES

Current market challenges

Main causes:

� Missing or wrong maintenance strategy

� Faulty or missing spare parts

� Faulty assembly and/or design

� Unidentified damage

� Communication deficits

� Lack of condition monitoring

Maintenance pitfalls

page 4

1 2

3 4

VisionMaintenance

excellence and valueadded for the customer

SafetyAvailabilityFlexibility

CostsCIP*

*CIP – continuous improvement process.

Bilfinger Maintenance

Concept

MissionPartnershipsService levelagreements

� Standardized, modular approach

� Use of best practice solutions from the Group

� Transparent, measurable and reviewable

� Most modern methods and tools

BMC® – Bilfinger Maintenance ConceptVision and mission

Module 16: Results of the maintenance analysisEvaluation on the basis of Best in Class and EFQM models

results

39.3%

39.6%

28.0%

45.9%

Management

Employees

Processes

Products

Services

Strategy / goals

Partnerships & resources

MaintenanceExcellence

36.8% 38.9% 43.8%

Costs

Availability

HSE

With the Bilfinger Maintenance Concept BMC®, today's reactive maintenance can be transformed into service-orientedmaintenance.

EFQM model

related

EFQM – European Foundation for Quality

Module 16: Results of the maintenance analysis Example of the consistent implementation of BMC®

Module 16: Bilfinger cooperation modelsFlexibility for any need

For a cooperation with our customers in the spirit of partnership we rely on:

� Competence � Quality� Reliability � Openness and the � Ability to change

Closely networked with our customers on the basis of longstanding experience

� we develop strategies

� we improve interfaces and processes

� we execute systematic knowledge management

Routine maintenance

Level 1

Workshop repairs& specialist services

Individual/project contract

Level 2

On-site, workshopand shutdown services, planned operations, emergency service & specialist services

Basic maintenance

Framework agreement

Level 3

Comprehensive maintenance services at the instruction of the customer / work packages with shared budget responsibility where necessary

Reduction to core team gatekeeping

Main contract

Level 4

Value performance services with fixed price.

The service provider has responsibility for the maintenance budget

Contract management key figure controlling

Value performance Contract

Based on a long-term partnership

Execution customer (own maintenance) Execution service provider

Initial situation

� Driver for cooperation: Improvement in termsof cost and availability

� Start: October 2001

� Reorganization, becauseall maintenance staff transfered to production

Module 16: Cooperation at Basis Service Level Reference example: Value Performance Contract

Challenge

� Short-term establishment of a completely new maintenance team with 8 employees� Public tender in 2012 let to extension of 5 years with option for a further 5 years

Steel Service Center in MannheimSteel Service Center in MannheimProject data

� Maintenance (inspection, repairs)

� Technical facility management

� Implementation of process optimizations,modernization and investment projects

Benefit

� > 20% savings on maintenance costs on the base line (defined initial situation)� Increase in plant availability from 89% to 98.5%� Reducing lead times through the optimization of automation� Increasing planned maintenance from 0% to 60%� Since 2001 no BG accidents, certified in accordance with SCC, take out log introduced

Implementation

� Introduction of SAP PM with Internet interface

� Introduction of maintenance strategy and key figures

� Introduction of RCFA, 5W, thermography, oscillation analysis, laser measurement technology, etc.

� Introduction of an integrated management system (HSEQ)