Project showcase

Maintenance Optimization Strategy

Project goal

To conduct a review of the Computerized Maintenance Management System (CMMS), and deliver recommendations that will improve the maintenance burden by implementing these changes through a series of maintenance optimization techniques.

Asset:

Offshore Gas Platform

Duration:

1 Month

Location:

Why We Were Contracted

The client was facing the following challenges:

Extreme over expenditure of maintenance budget
Not enough resources to liquidate the maintenance work orders
Inability to showcase an auditable maintenance history to HSE

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 around the content, structure and applied maintenance which was benchmarked against typical industry standards as well as Add Energy experience with similar assets, with the intent to identify opportunities for optimization. The review covered:

The structure and content of the functional location hierarchy
Frequency of the PM’s
Duration of PM’s
PM description and work instructions

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

Identified over $1.5M of planned maintenance that wasn’t required
60% of criticality scoring was wrong, making it difficult to apply the correct level of maintenance
25 class codes were missing a maintenance strategy
65% of tags had no equipment types allocated, making it difficult to document corrective work at the correct level
Based on Add Energy’s experience, the allocated man hours/ tool time assigned to PM work orders were externally excessive causing an unrealistic burden on both man power and ability to schedule work

Benefits and Deliverables

Over $1,791,800 of annual planned maintenance savings by optimizing the frequency of existing maintenance activities and duration of tasks to clarify tool time durations
50% of the man hour savings were derived from optimization of the asset were derived from optimization of the assets “lifting systems” planned maintenance
Associated cost savings were provided through the scope of work, as well as a reduction in the risk of safety related incidents by reducing the number of personnel required offshore per year
Reduced workload burden by implementing the ability to group, package and nest maintenance