ABOUT THE CLIENT

Metalusa, part of a prominent business group, specializes in the production of metallic equipment, structures, scaffolding, formwork, and associated industrial services. The company is involved in projects spanning diverse sectors, including Construction and Rehabilitation, Energy and Industry, Events and Shows, and Infrastructure.

Metalusa’s industrial operation is distributed across several factory units, each with distinct productive sectors. These operations rely heavily on critical industrial equipment, such as production lines, overhead cranes, forklifts, auxiliary systems, and specialized cutting, bending, and welding machinery.

PROJECT KICKOFF

The implementation of the ManWinWin CMMS at Metalusa began over 5 years ago with clearly defined strategic objectives essential for consolidating its complex, multi-site maintenance management:

• Equipment Centralization: Consolidate management of all equipment into a single system.
• Preventive Management: Systematically manage preventive maintenance (PM) routines.
• Alerts and Communication: Establish effective maintenance alerts and communication channels.
• Request Management: Formalize and track all maintenance requests.
• Work Order Scheduling: Centralize and manage the scheduling of Work Orders (WO).
• Historical Tracking: Group complete maintenance history by individual equipment.
• Materials Management: Control spare parts and inventory.
• KPI Creation: Generate reliable maintenance indicators for performance analysis.

IMPLEMENTATION PROJECT

Based on the ambitious objectives, the implementation was structured around key activities to build a robust and scalable CMMS foundation:

• Functional Organization: Creation of a functional organization structure to support future expansion, standardization, and logical aggregation of data across all factory units.
• Equipment Registration: Comprehensive registration of all equipment, including technical documentation, photographs, association of spare parts, and initial logging of operational readings.
• Preventive Plan Definition: Definition of maintenance plans with standard work sheets detailing mechanical, electrical, hydraulic, and pneumatic tasks. This was managed via programmed Work Orders.
• Web Request Configuration: Implementation of the web-based maintenance request module for production floor operators, ensuring seamless and timely communication between Production and Maintenance teams.

PROJECT IMPACT

The implementation of ManWinWin allowed Metalusa to achieve profound improvements in operational governance and efficiency:

• Standardized Structure: Creation of an organized and standardized structure for its entire equipment park.
• Systematic PM: Introduction of systematic preventive maintenance routines, leading to reduced failures and increased operational reliability.
• Cost Visibility: Increased visibility of costs, intervention times, and resources applied across all maintenance activities.
• Centralized Communication: Centralization of requests, which eliminated information loss and dramatically improved communication between production and maintenance departments.
• Indicator-Based Improvement: Initiation of a continuous improvement process driven by key indicators aligned with the EN 15341 standard (covering availability, costs, and performance).

CONCLUSION

The implementation of ManWinWin at Metalusa represented a decisive step toward professionalizing and digitalizing maintenance. The project successfully structured the equipment park, standardized procedures, implemented robust preventive plans, and ensured greater control over costs, times, and interventions. By fully meeting the defined objectives, Metalusa now operates with a robust, scalable system aligned with world-class maintenance management best practices.