Tata Motors needed qualified specialists for the maintenance and repair of the state-of-the-art equipment and machinery installed during the construction project. By signing the performance-based maintenance agreement with Siemens, the car manufacturer wanted to optimize its maintenance cost, reach defined key performance indicators (KPIs), and ensure a required level of plant availability for certain production areas without hiring additional maintenance staff.

The Plant Maintenance Service contract was signed on the basis of jointly agreed KPIs, including defined plant availability of more than 98 percent for the body/welding shop and paint shop as well as the power supply and distribution. A new performance monitoring system makes it possible to control the KPIs. To meet the contractually agreed KPIs, Siemens service experts implemented a wide range of improvement measures for plant reliability including computer-aided failure analysis (CAFA) and root cause failure analysis (RCFA). A newly installed energy management system delivers daily reports on the actual energy and fuel consumption, power outages, downtime and maintenance work. Other key figures such as health and safety spare part consumption and stock turnover as well as the share of maintenance work completed are reported monthly. Condition-based maintenance, spare part analyses and proposals for improving plant reliability to optimize the cost of maintenance and spare parts.