Maintenance Benchmarking and Optimisation Study
Client: Onshore Gas Plant
Duration: 2 months
Project Objective: To rationalise the maintenance expenditure through a strategic roadmap for optimisation and reduction of maintenance, whilst assuring the integrity of equipment
Location: Caspian Sea
Challenges faced by the client
Below is a summary of the challenges that the client faced prior to engaging with ABL:
- 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
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. Below is 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
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
$7.1m
Saved in 6 months by removing unnecessary PMs
$20m
Saved in 1 year by rationalising PMs and optimising frequencies
PMs
Safety critical equipment now have PMs assigned