Creating structure and insight in electrical systems for a global pharmaceutical manufacturer
Our client, a global pharmaceutical manufacturer, wanted to reduce operational risks related to non-GMP electrical systems. Aging components, limited lifecycle insight and unstructured spare-part data made maintenance increasingly complex. PDM created structure across the E&I asset base, combining asset mapping, standardization, criticality assessment and lifecycle management. The result: better insight into operational risks, faster maintenance and a more controlled spare-parts strategy.
OUR CUSTOMER
THE CHALLENGE
Limited insight into electrical assets
Electrical systems had long been considered non-critical, resulting in limited documentation and lifecycle insight. With more than 900 electrical cabinets, there was no uniform overview of components, condition and criticality.
Aging and obsolete components increased operational risk
When a generator component became obsolete and no direct replacement was available, the lack of lifecycle visibility became an immediate operational concern. Without structured insight into obsolescence, risks could only be addressed reactively.
Unstructured spare-part data slowed maintenance
Spare-part information was not consistently linked to individual assets. Technicians had to search through large amounts of data to identify the right component, increasing Mean Time To Repair (MTTR).
Balancing availability with inventory costs
Without clear insight into asset criticality and lifecycle status, determining which spare parts actually needed to be kept in stock was difficult. This created unnecessary inventory while still leaving uncertainty around the availability of critical components.
Building excellence together
PDM started by creating a structured baseline of the complete E&I asset landscape.
All E&I assets were inventoried and mapped. Components and spare parts were then structured within a standardized E&I framework and linked to the relevant assets. This created transparency across more than 900 electrical cabinets and made component information directly accessible for maintenance.
Asset criticality was assessed to identify where failure would create the greatest operational risk. Combined with lifecycle information, this made it possible to identify obsolete components, determine replacement options and prioritize maintenance activities.
From this foundation, PDM developed a more focused spare-part strategy. Instead of managing inventory as a separate activity, spare-parts decisions could be connected directly to asset criticality, lifecycle risk and maintenance requirements.
The approach was piloted at one plant and designed for scalable rollout across other locations.
THE IMPACT WE MADE
- 20 % reduction in spare parts inventory
- 5% reduction in MTTR
- Lower risk of operational downtime
- reater lifecycle transparency
Facing Similar challenges?
PDM supports asset-intensive, multi-site organisations in implementing uniform asset management approaches that strengthen control and alignment, compliance and operational performance across locations.
OUR APPROACH in action
We don’t just create an asset register. We connect technical asset information to the maintenance and lifecycle decisions that determine reliability.
E&I asset mapping and criticality. Creating a structured overview of electrical assets and determining which components pose the greatest operational risk.
Structured assets and spare parts. Standardizing component data and linking spare parts directly to the assets where they are used.
Lifecycle and obsolescence management. Identifying obsolete and aging components early and creating visibility into replacement requirements.
Risk-based spare-parts strategy. Using asset criticality and lifecycle information to balance availability with inventory costs.
Scalable asset structures
Establishing a standardized approach that can be extended beyond the initial plant.
