PROJECT SHOWCASE

Maintenance Benchmarking and Optimisation Study

Client:

Onshore gas plant

Location:

Caspian Sea

Duration:

2 months

Our approach

We analysed the client’s existing planned maintenance data and benchmarked the findings with best practice maintenance data across similar asset types, to identify immediate, quick win gains, as well as long term implementation improvements.

Known issues:

Maintenance expenditure was extremely high
Corrective maintenance ratios were higher than planned
Significant reliability issues in relation to the equipment across multiple assets

Our methodology:

Data collection and review
Maintenance benchmarking
Engineering analysis and interpretation
Peer review with subject matter expert maintenance consultants
Identification of improvements
Impact assessment
Delivery of improvement roadmap based on ROI, effort and risk

Software used

Aim-Hi™, Add Energy’s maintenance strategy benchmarking and alignment tool, analysed the client's documentation and computerised maintenance management system (CMMS) data.

The information analysed included:

Maintenance strategies
Maintenance frequencies
Man hour utilisation

Initial findings

Extreme differences in application of maintenance frequencies and activity types across units
High number of PMs were unnecessary and too frequent
Disproportionate planned hours in task lists
No use of failure codes in failure reporting
High proportion of maintenance short text was wrongly allocated to equipment
SCEs with no PMs allocated
High percentage of maintenance recorded against locations had no object types

Results

41 improvement changes identified
$7,100,000 saved in 6 months by removing unnecessary PMs
$20,000,000 saved in 1 year by rationalising PMs and optimising frequencies
Safety critical equipment now have PMs assigned