VolvoA hybrid maintenance organization for maximum efficiency

The Task
The VDM (Value Driven Maintenance) model developed by Mainnovation was used as a central framework. All existing and ongoing initiatives and best practices (TPM, Six Sigma, etc) were linked to the corresponding competences in the VDM model. For the first time, various plants in Sweden and Belgium were now using a common maintenance model. The model was then used as a basis to develop work processes and IT tools. The model’s simplicity assured broad acceptance throughout the organization.
The two improvement circles focused on technical availability and costs are fully in line with business needs. Since the auto industry has a cyclic character, it is important for the current value driver to be known and for the organization to act accordingly.

The Approach
In his capacity as maintenance manager of Volvo Cars Ghent, Marc Begijn designed a maintenance organization capable of executing maintenance processes as lean, agile and effectively as possible. This resulted in a hybrid organization in which the daily maintenance support for corrective activities remained decentralized across the various production departments. All maintenance activities outside the normal production periods, such as preventive maintenance, are centralized in the various production departments. This makes it possible to organize Reliability Engineering and the complete scheduling and planning process in an efficient manner. Marc Begijn was voted Maintenance Manager of the Year in June 2013. This fall, Marc Begijn was appointed Bodyshop Manager. Guy Leys currently occupies the Maintenance Manager position. The plant produces 250,000 cars per year at a rate of one car per minute.

Mainnovation’s Added Value
The plant in Ghent produces the V40, S60 and XC60 models. The plant produces 250,000 cars per year at a rate of one car per minute. It is a highly automated plant with 828 robots and a total assembly line length of 15.7 kilometers. The assembly department’s technical availability is 98.7%.