Asset Strategies
for Dairy Plants
ASSET STRATEGIES
for DAIRY PLANTS
DAIRY PROCESSING APPROACH
From milk intake to finished product…
AMSYST applies the right approach to each part of the dairy plant, while keeping the whole operation connected.
PRODUCTION & PACKAGING
Product processing, filling, packing and end-of-line equipment
→ Explore the approach
SITE UTILITIES
Steam, refrigeration, water, compressed air and supporting infrastructure
→ Explore the approach
PROVEN IN DAIRY
Dairy experience built into AMSYST
YEARS
deployment of the AMSYST methodology
DAIRY PLANTS
implementations in New Zealand and the US
ASSETS
reviewed (rotating equipment, instruments, valves, vessels and more)
From tribal knowledge, empirical strategy and incomplete data
To robust, structured and sustainable strategies, based on actual risk
AMSYST IN ACTION
How dairy asset strategy comes together in AMSYST.
1
Build the master data foundation
Create a reliable view of the plant and the context needed to make better asset decisions.
Turn existing P&IDs and plant knowledge into a structured view of how the process actually operates.
Start with the process
Identify functional systems and boundaries based on how the process actually works, rather than grouping assets by drawing, tag convention or equipment type.
Build the hierarchy
Translate those process areas into a structured functional hierarchy, placing equipment within the function it supports and following the process flow.
Position assets on plant layouts and capture the access constraints that affect how maintenance is performed.
Know where the asset is. Understand what is needed to access and isolate it.
Reduce time wasted locating equipment, arranging access and preparing the job safely.
2
Assess the risk
Combine equipment failure behaviour with process and product context to determine criticality and annualised risk.
Build reusable models for each equipment class, capturing functional failures, failure behaviour and likely consequences.
Map process dependencies, buffers and reduced-capacity operation so downtime reflects how the plant actually runs.
Combine the risk model with process and product context to calculate annualised risk exposure.
3
Build the strategy
Build reusable PM models, then deploy the right strategy consistently across the plant.
Define the tasks with frequencies, resources and applicability for each equipment class.
Match the appropriate PM models to assets across the hierarchy, turning reusable maintenance logic into asset specific strategies.
4
Turn strategy into executable work
Convert the PM strategy into a practical maintenance program ready for execution.
Group tasks by frequency, operating state, labour and location to create practical maintenance routes.
Review plan details and overall duration, then release the finished maintenance plans.
Spread recurring work across the year to balance workload and align with maintenance windows.
Publish the finished work as printable PM documents or digital routes, complete with maps, task detail and execution guidance.
Printable PDF Document
Mobile Application
REAL DAIRY RESULTS
From a boiler pilot to a broader asset strategy
Oceania Dairy started with a focused boiler pilot. The work exposed gaps in master data, criticality and PM strategy, then created a structured foundation that could be extended into the main dryer plant, utilities and other production areas.
Assets reviewed
(Criticality & PM Strategy)
(Criticality & PM Strategy)
Maps created,
6,500+ Assets positioned
6,500+ Assets positioned
PM Plans defined,
24,000+ individual tasks
24,000+ individual tasks
When you are responsible for asset reliability, AMSYST gives you peace of mind. You know where the risks are, the assets are covered, and nothing is hidden.
Ian Harrington – Instrumentation & Reliability Lead
WHAT’S NEXT?
GET IN TOUCH
Tell us what you need, and we’ll help you find the right next step
