Holistically expanded maintenance management as an effective optimization tool for the process technologist

Thinking beyond

The premium car manufacturer BMW Group has been relying on its partnership with ISOware since 2007. Throughout the world, [sip] supports the group’s engine plants along the entire process chain in production. This is achieved, on the one hand, by means of holistic media management that looks "beyond the horizon" of the individual processes of machining – washing – preservation and, on the other hand, by means of integrated information management that takes into account analysis data from the process laboratory as well as particle counting of technical cleanliness.

A powerful steering tool

On this basis, [sip] was created as a powerful steering tool for process technologists – with an economic and ecological perspective that offers both live monitoring of the current situation and regularly provides valuable information for systematic improvement. For this purpose, KPIs such as cost-per-unit or "lubrication performance" are continuously determined from current production figures and measured values. At the same time, these enable genuine benchmarking between the individual plants.

Fluid circuits
Measuring points
Measuring tasks
Measurement data

The role of [sip]

[sip] is central to the conversion of relevant data into live charts and systems for quality and audits.

In addition, the foundations are laid for business cost calculations and comparisons, for the preparation of risk assessments and operating instructions for occupational health and safety and for sustainable management, i.e. the identification and implementation of resource savings in energy, water, waste water and waste.

[sip] at the Steyr engine plant

For BMW’s machining operations, [sip] is the tool for uniform management of technical information. The solution offers group-wide benchmarking across all affected locations on the basis of meaningful factual key figures.

The first roll-out took place in 2007 at the engine plant in Steyr, where a good 60% of all chips in the entire group are produced. The goal on site was initially to consolidate the heterogeneous systems that had existed there until then in the areas of:

  • Cooling lubricants
  • Washing machines
  • Process documentation "technical cleanliness"
With the help of [sip], we were able to significantly reduce our cost-per-unit in fluid management in just one year. We now have a secure process and improved transparency in the process parameters. Thus, the certification according to ISO TS 16949 always runs smoothly.
Hartmut KörberProcess Technology Fluid - BMW Steyr

Fluid management with [sip]

[sip] collects all relevant information in a central location:

  • Process media
  • Suppliers
  • Collection of all relevant measurement and consumption data
  • Online monitoring of the defined tolerance fields of all measured variables
  • Notification of the process participants in the event that the tolerance fields are exceeded
  • Clear presentation of the collected data in analyses

[sip] as a holistic instrument

Instrument for economic efficiency

By analysing the data, consumption of process media, filters, water and also overtime can be reduced. In addition, leakages are detected earlier and maintenance intervals are optimised.

Instrument for quality

Faults are detected in real time and immediately assigned. A closed quality control loop is created. The ideal proof for audits.

Instrument for occupational safety

All process media with all parameters and changes are recognisably assigned – for employees and company doctors.

Instrument for sustainability

Energetic changes in facilities, water and waste water consumption are recorded, clearly show optimisation potential and can be used by auditors.