A large German online mail order company entrusted the current interim manager with ensuring the operation of material flow technology and building technology for logistics sites in Germany and Europe (Poland, Italy, Netherlands). He was to achieve the highest possible system availability and excellent working conditions at the lowest possible cost. Driven by strong growth, the Group worked with many interim solutions at the start of the project. There was no strategy for the operation of facilities and buildings.
Analysis of material flow and building technology at two locations
The interim manager first analyzed the operation of the material flow and building technology at two existing logistics locations. In doing so, he identified a number of deficiencies. For example, the technical operator organization lacked processes for legally compliant proof of maintenance and for dealing with technical failures. Even more serious were errors in the electrical installation and ventilation technology, which impaired reliability, working conditions for employees and energy efficiency.
In a first step, the interim manager developed processes for legally compliant documentation of maintenance and dealing with technical failures. The interim manager optimized plant monitoring by expanding the recording of possible technical failures and coordinating the procedure for error messages in such a way that plant availability improved significantly.
Faulty electrical installations and ventilation technology optimized
The interim manager then set about eliminating important technical defects. For example, planning errors in the electrical installation had led to repeated malfunctions in the system. Conversions ensured that the installations no longer caused any disruptions.
One of the larger sub-projects was the optimization of the ventilation technology. The adjustments initiated by the interim manager ensured that the working conditions of the employees (room temperature, humidity) improved significantly. At the same time, the optimized ventilation technology consumes significantly less energy (energy efficiency).
Operator concept developed for material flow and building technology
In order to avoid a repetition of such and similar deficiencies in the planning of other locations, the interim manager and his team developed an operator concept for material flow and building technology. The operator concept included a complete revision of technical specifications, a comprehensive process landscape and guidelines for the organizational structure. The standard developed in the area of occupational health and safety and working conditions met the highest country-specific requirements.
Service management set up to improve plant availability
In order to improve plant availability, the interim manager implemented a service management system. In doing so, he drew on proven ITIL processes. At the same time, he organized the service management across departments. For example, he involved IT teams in the process description. Breaking down silo thinking played a key role in eliminating sources of error during system fault clearance and commissioning.
In addition, the interim manager used digital tools (condition monitoring, simulation, digital twin) to create and roll out concepts for improving availability and increasing throughput together with external specialists.
In order to enable all teams to learn across all sites, the interim manager established a permanent exchange between the sites and a wiki to improve troubleshooting and error prevention strategies across all sites.
High plant availability ensured while reducing costs
The interim manager successfully completed the project. Plant availability had increased significantly. The working conditions not only met the requirements, but were also recognized by the workforce and employee representatives. The shared use of systems, tools and specialist departments (electrical and automation technology) by material flow technology and facility management generated synergies and reduced operating costs
