Maintenance Optimization

Helping companies achieve performance excellence

Assure reliability and unlock efficiencies across your maintenance management regime.

At Add Energy, we utilize our award-winning software, world-class maintenance standards and highly experienced experts to identify and implement maintenance optimization tactics designed to safeguard production and minimize operational expenditure.

Gain access to maintenance optimization solutions that are guaranteed to:

Protect your people, plant, and the environment

Through the implementation of best-in-class maintenance procedures and performance standard assurance tasks, minimize your exposure to risk or incident

Minimize plant and equipment downtime

By mitigating identified failures through optimized equipment management strategies and execution plans, we can help minimize equipment outage and plant downtime

Optimize operational and maintenance expenditure

Assuring the right maintenance is done at the right time, with the right materials, at an optimized frequency – no more no less, derived from independent experts

Mitigate unhealthy maintenance backlog

Implement a fully optimized maintenance plan and schedule to maximize maintenance execution tactics and time available to liquidate work effectively

“Plant reliability is one of the most noticeable outputs of this project; not only are we setting record reliability statistics, but we are achieving this with optimized levels of maintenance, don’t at the right time, in a globally consistent manner.”

Director of Maintenance, International Energy Producer

How we can help

Maintenance performance benchmarking

3rd party maintenance improvement studies
3rd party CMMS data analysis and improvement recommendations
Maintenance management KPI development and analysis
Asset health check audit

Water oil or gas pipeline valve closeup new PGVYH4 R

Maintenance strategy optimization

RCM studies and facilitation
FMECA
Equipment maintenance strategy development
Equipment maintenance strategy optimization
Maintenance Bill of Materials (BoMs)
Maintenance task criticality assignment
Equipment reliability analysis
Equipment vulnerability analysis
Late life extension studies
Decommissioning maintenance strategy optimization
Obsolescence studies

Maintenance management system optimization

Work order packaging, routing, and nesting
Work order sequencing
Work order smoothing and load-levelling
Backlog rationalization studies

Work execution support

Root cause analysis
Maintenance management KPI analysis
Backlog rationalization studies
Competency assessment
Maintenance management training and coaching
CMMS utilization training
Supply of maintenance management technical advisors and subject matter experts
Supply of data scientists and CMMS analysts

Uncover maintenance optimization tactics for your plant

Benchmark your maintenance management regime against industry peers and best-in-class maintenance data to identify opportunities to:

Improve reliability
Save money
Work smarter

Discover more

Our proven results

Our solutions have been proven to increase plant uptime and unlock significant cost savings and efficiency gains for our global clients, across multiple industries.

Some of our results include:

Savings of over $18.5M per year by optimizing annual planned maintenance hours 
Savings of $7M per year through optimization of annual planned maintenance work orders
Enhanced production uptime by 11% through maintenance optimization tactics identified by Add Energy

Sign up to receive regular insights and advice around maintenance optimization

Our maintenance optimization software and technology

Our award-winning software has been designed to improve the interface between people and data, harnessing machine learning and industry 4.0 to revolutionize the way businesses operate.

4 reasons why you should consider utilizing Add Energy to optimize your maintenance management regime

Through a cost-free initial review and consultation, we can recommend where best to focus your efforts and budget to solve your maintenance management challenges

Born from a shared team mission to relentlessly pursue solutions that unlock business efficiencies– we will not commit to a project without a guaranteed ROI for our client

Access tried and tested technology that is capable of solving real-world maintenance management challenges in a timely and cost-effective manner

Harness technology and highly experienced maintenance experts to implement quality assured and future-proof solutions

"On behalf of Stena Drilling, may I thank you and your excellent team for the effort put into our recent maintenance reviews and stock criticality reviews.

Having used the services of Add Energy over a number of years, we have seen great results and a continuous improvement in our equipment reliability and availability which has helped Stena Drilling to become one of the world’s leading drilling contractors. The annual maintenance reviews pay for themselves year on year and are a valuable tool in our arsenal when aiming for zero downtime.

Often the results of well planned maintenance activities or day to day running of the stores go unnoticed. But by using the knowledge of Add Energy we have continued to improve year on year and look forward to working with Add Energy in the future."

Gareth Falls, Maintenance Superintendent, Stena Drilling

A high performing plant is one that is safe, efficient, reliable, and profitable and there are many critical success factors that come into play when it comes to striving for excellence.

The philosophies cascading into the management systems and processes influences all 4 elements of what it takes to be a high performer. Without a meticulously designed and executed CMMS resulting from this, plants are subject to increased risk of equipment failure, loss of production, and excessive maintenance costs – which will directly impact the safety integrity and performance of the plant.

To truly optimize a plant’s maintenance and materials regime and unlock the associated benefits that come with it, it is key to build this regime using reliable, structured, and quality master data. Realizing the need to have this in place, Add Energy were contracted by an international energy company to deliver a global maintenance optimization project where we were tasked with enriching the CMMS data and optimizing the maintenance management regime, and associated spare parts in excess of 1.3 million equipment tags.

The challenge

To assure the right level of preventative and predictive maintenance and inspection, on the right equipment, was being done with the right materials, at the right time – no more, no less. Achieved through:

Efficient and effective warehouse management relies on good quality and accurate data, fit for purpose processes and technology and a competent team. When any of these key success factors are compromised, a business is likely to experience:

Wasted expenditure

Time delays

Production deficits

Poor productivity

1. Poorly managed preservation maintenance

“For some items, preservation maintenance is required to assure they function as they should when they are required.

“The requirements for conducting preservation maintenance can make it difficult to keep track of the locations of critical items due to the maintenance log needing to be manually updated on a regular basis to reflect their condition change, I.e., their location or maintenance being completed. Some businesses may have specialist workshops miles away from the main warehouse, meaning stock that requires specialist preservation maintenance is subject to movement and therefore loss of control.

“If these condition changes are not updated in the digital inventory management system, or CMMS, this may result in items not being able to be located, confusion on whether it is available for use and exposure to risk, because the warehouse team are unsure if the item is safe for use because there is no record of it being maintained whilst in the warehouse, as per its requirements.

“In addition to this, in my experience, poorly managed preservation maintenance can also cause stock to perish quicker over time because there are no triggers or notifications for maintenance requirements, which may result in premature failure of equipment once installed and the need to replace the part at late notice, at a premium price point.”

An aging plant is one that has typically been operating over several decades and is likely to have gone through significant changes, ranging from modifications to expansions and design changes. As the asset gets older, there are several challenges that will inevitably arise, such as over or under maintained equipment, difficulties purchasing spare parts or changes in operating conditions that can lead to corrosion, erosion, mechanical damage, and other late life degraded failures.

Danny McGowan, Operations Manager at Add Energy, has 30+ years' experience in the oil and gas industry and has worked on asset management and process safety improvements projects for several aging assets throughout his career. In this blog post Danny discusses the top common challenges associated with aging assets and provides helpful tips on how to overcome them.

Efficient inventory and spare part management is a fundamental requirement for achieving business performance goals and mitigating risk.

And unfortunately for us, a crystal ball for pinpointing exactly when you will need a spare part does not exist for helping to decide which spares should be kept in stock, how many you should hold and where they should be located. But what we can do to help inform stocking decisions is assess the factors that are directly linked to accessing the spare part you need. This should include data and information relating to the risk profile, lead times, storage costs, costs of loss and demand rates.

A safe asset is a reliable asset, and a reliable asset depends on sufficient equipment management strategies and risk mitigation barriers being put in place and adhered to through a systematic approach to asset management.

To achieve this, companies must consider harnessing technology advances. With mass redundancies and cost cutting initiatives occurring all over the world in the wake of COVID-19, a transition to utilizing and adapting to “Industry 4.0” technology is more critical now than it ever has been.

Maintenance Optimization

Assure reliability and unlock efficiencies across your maintenance management regime.

At Add Energy, we utilize our award-winning software, world-class maintenance standards and highly experienced experts to identify and implement maintenance optimization tactics designed to safeguard production and minimize operational expenditure.

Gain access to maintenance optimization solutions that are guaranteed to:

How we can help

Maintenance performance benchmarking

Maintenance strategy optimization

Maintenance management system optimization

Work execution support

Uncover maintenance optimization tactics for your plant

Our proven results

Sign up to receive regular insights and advice around maintenance optimization

Our maintenance optimization software and technology

Efficient maintenance strategy development

Optimize maintenance expenditure

Controlled optimization of maintenance data

Build an accurate asset register

Control and automate Management of Change

4 reasons why you should consider utilizing Add Energy to optimize your maintenance management regime

Faisal Al-Humaidi

Andrew Gardiner

Afia Mcclenaghan

Get in touch

Track record

Technical Integrity and Asset Lifetime Extension Assessment

Asset Vulnerability and Life Extension Study

Warehouse and Inventory Management Optimization

Development of an asset management and maintenance program

Asset and Integrity Management Blog

Achieving safety integrity assurance and performance excellence through a data-driven maintenance improvement project

A high performing plant is one that is safe, efficient, reliable, and profitable and there are many critical success factors that come into play when it comes to striving for excellence.

The top 4 barriers preventing your ability to achieve efficient warehouse management

Efficient and effective warehouse management relies on good quality and accurate data, fit for purpose processes and technology and a competent team. When any of these key success factors are compromised, a business is likely to experience:

6 ways to save time and money in materials and spare part management, using your CMMS

How to drive performance and optimize costs by unlocking the potential of your maintenance and reliability workforce

Unlocking the potential of your maintenance and reliability workforce through competency improvement programs is proven to minimize exposure to risk, boost company performance and optimize costs.

Overcoming common challenges associated with aging plants

3 fundamental processes guaranteed to unlock maintenance efficiencies and ensure plant reliability

An operating plant is subject to significant changes throughout its lifecycle, ranging from new owners to plant upgrades, design changes and expansions. When these changes are not managed correctly this can incur exposure to safety issues, downtime and unnecessary costs.

Key considerations for setting optimal min/max inventory stock levels to assure productivity and profitability

Efficient inventory and spare part management is a fundamental requirement for achieving business performance goals and mitigating risk.

Harnessing “Industry 4.0” to safeguard asset integrity: Initiatives for unlocking efficiencies to protect your people, plant and processes

A safe asset is a reliable asset, and a reliable asset depends on sufficient equipment management strategies and risk mitigation barriers being put in place and adhered to through a systematic approach to asset management.

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