Project showcase

Maintenance Benchmarking and Optimization Study

Project goal

To rationalise the maintenance expenditure through a strategic roadmap for optimization and reduction of maintenance, whilst assuring the integrity of equipment

Client:

Onshore Gas Plant

Duration:

2 Months

Location:

Caspian Sea

Software:

Aim-Hi™, Effio™

Our approach

We analyzed 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.

Challenges

Below is a summary of the challenges that the client faced prior to engaging with Add Energy:

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

How We Helped

An overview of our approach:

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, analyzed the client's documentation and computerized maintenance management system (CMMS) data.

The information analyzed 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