Project showcase

CMMS Gap Analysis & Planned Maintenance Optimization Study

Project goal

To conduct a review of the Computerized Maintenance Management System (CMMS) currently being utilized, including the planned maintenance regime, to identify opportunities for optimization.

Asset:

Gas Plant

Duration:

1 Month

Location:

Europe

Why We Were Contracted

The client was facing the following challenges:

Absence of quality asset register data
The CMMS was not set up adequately to allow for an optimized planned maintenance schedule
No packaging, nesting or routing of maintenance was built into the planned maintenance regime
Inability to prioritize maintenance due to poor criticality assignment

Our Approach

An initial data analysis was performed to identify any gaps, inconsistencies and recommendations for improvement in the data provided by the client.

This scope of work focused on the review and analysis of the CMMS data content, structure and associated maintenance. The study conducted by Add Energy benchmarked the data and maintenance against industry best practice standards, as well as Add Energy experience derived from projects with similar assets, with the intent to identify opportunities for optimization.

The review covered:

The structure and contents of the functional location hierarchy
A sense check of the assigned criticality and classification of equipment types
Frequency of the PM’s
PM work order descriptions

What We Did

Data collection and review
Workshop to agree key assumptions with the asset stakeholders
CMMS Gap Analysis
Planned Maintenance Benchmarking Study
Delivery of results and prioritised implementation plan based on risk, return on investment and criticality

Initial Findings

86% of tags had zero maintenance assigned to them
383 tags of these tags were assigned as “high criticality” yet had no maintenance assigned to them
32% of the data analyzed had no estimated hours or labour allocation, making it difficult to plan and schedule maintenance
$148,000 was being spent per year to manually schedule and prepare planned maintenance that could be automated through optimized foundational data and utilization of the CMMS
5,733 annualized man hours of maintenance could be removed following optimization

Benefits & Deliverables

$456,000 of annual savings were identified by optimizing the frequency of existing maintenance activities and time spent on manually scheduling planned maintenance
Over 10,000 hours planned maintenance man-hours could be saved through the implementation of the optimization recommendations provided by Add Energy
7 days per month saved on admin time that was previously spent manually scheduling maintenance by unlocking efficiencies in the CMMS functionality