Dipl.-Ing. Karl-Heinz Mayer

Consulting Services: - Development of maintenance program and maintenance strategy - Execution of Asset Management Assessments - Development of maintenance processes - Reliability Engineering and GxP Asset Management Processes - Implementation and optimization of Asset Management Organization - Implementation of Condition Based Maintenance - Implementation and usage optimization of Asset Management Systems (e.g. SAP-PM)

Asset Management consulting Services for Mercer Stendal - Plant shutdown planning and scheduling - Sustainability of Asset Management Processes - Implementation of Reliability processes

Development of an Asset Mangement Assessment Audit tool accoring ISO 55000 Execution of Asset Management Assessments and Audits Implementation of Total Productive Maintenance in Novartis Development and implementation of standard asset management business processes for the Novartis manufacturing sites in Asia, Europe and USA.

Implementation of SAP-PM in the Novartis manufacturing sites Implementation of SAP-PM business processes e.g. Corrective Maintenance, Preventive Maintenance, Planning and Scheduling of Maintenance and Calibartion of Instruments Development of a SAP-PM best practice guide in order to harmonize and improve the usage of SAP-PM accros the Novartis manufacturing sites Leading and guide the SAP-PM super user community Review of all SAP-PM service requests

Implementation of Total Productive Maintenance (TPM) in all Novartis pharma manufacturing sites Definition of the implementation strategy together with the manufacturing (e.g. Maintenance Strategy for 14 TPM work streams) Execution Asset management Audits and Assessments Definition and implementation of maintenance processes

Development of a maintenance program for the new site vaccines manufacturing site in Marburg, Germany Defining an equipment (Floc) structure for production and utility equipment Development of the Asset Life Cycle documentation SOP for the new manufacturing site

Execution of process equipment designs for 3 new chemical production buildings Leading the Project Engineers of the CN Design Engineering contractor(SSEC) in Shanghai/ China in order to achieve the design requirements of the project URS Release and control of all asset material specification Auditing OEMs and advice the project purchasing organization in order to select the right equiment amnufacturer

Managment of the site engineering team (5 Engineers) Responsible for a maintenance budget ca. 3 MCHF Creation of a 3 year investment plan, preparation of the annual project budget and execution of projects Responsible for project schedule and costs in compliance with internal and external cGMP guidelines Responsible for process optimization and changes of production and utitlity equipment Explanation the the maintenance organization, processes and results to pharmaceutical authorities e.g. FDA

Realisation of environmental projects, building of waste water treatment plants and waste incineration plants within the CIba-Geigy production sites Project Manager of a new WWT plant for a chemical production site in France, Project budget 10 M€ Consultant for external companies in the area of environmental processes and in the definition of user requirements

Development and standardize of an cost code structure for investment projects of the central and site engineerings Roll-out of the stanardized cost code in the central engineering and site engineerings Support the central project engineers in setup the cost structure for large investment projects Calcluation, creation and publishing engineering key figures/ indicators for investment projects within the engineering community

Support the startup process of new packaging equipment in order to achieve the expectect assets performance (OEE) before handover to production Carrying out weak point analysis on packaging and process equipment to improve OEE Reduction of corrective maintenance by improving preventive maintenance Savings: 1 M€ production per year

Applied economics

Mechanical and Industrial Engineering