Maintenance Strategy Optimisation
Maintenance strategy optimisation is the key to hitting production targets safely and consistently. It is important to fine-tune your plans based on current operational requirements, lessons learned, data analysed, industry best practices, new techniques, new technology and so much more.
We’ll work with your team to optimise your plans, by either conducting a full analysis and optimisation project or by supporting your in-house team in delivering specific components.
ABL’s experts, world-class maintenance standards and award-winning software will help you identify and implement maintenance and reliability best practices to safeguard production and minimise operational expenditure.
Our maintenance optimisation consultants and analytical software can:
Analyse
Thoroughly explore your maintenance data and strategies
Benchmark
Benchmark your maintenance regime and plant performance against industry best practice
Investigate
Fully investigate problem areas and identify opportunities for improvement
Implement
Deliver a highly detailed action plan for optimising your maintenance management regime
Past project 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.
$18.5M
Savings of over $18.5M per year by optimising annual planned maintenance hours.
$7M
Savings of $7M per year through optimisation of annual planned maintenance work orders.
11%
Enhanced production uptime by 11% through maintenance optimisation tactics identified by ABL.
Our reliability and maintenance solutions
As experts in maintenance and reliability best practices, we can work across a wide range of areas where we can help optimise your projects.
Maintenance optimisation and analysis
Equipment vulnerability analysis
An independent evaluation of the risks for equipment or assets across key areas of engineering, reliability, spares, maintenance and economics. We provide a current threats ranking and forward plan that will improve or maintain your current risk levels.
Equipment reliability analysis
An independent evaluation of an asset, system, or equipment’s reliability, as well as looking at improvement opportunities or highlighting key tasks that are currently being conducted to maintain your reliability goals.
Late life extension studies
A review of assets that are at the end of or beyond their design life, and identifying the actions required to safely operate them beyond that timescale.
Equipment maintenance strategy development
Using either our very own RCM-based maintenance library or developing bespoke strategies for clients, we can provide a maintenance solution for any asset situation to ensure safe and efficient operations are justified, planned, and scheduled.
Obsolescence studies
The identification and categorisation of equipment or systems that are approaching or have become obsolete, and providing options to deal with continued operation or replacement plans.
Equipment maintenance strategy optimisation
We can work with you to ensure industry best practice is applied across your organisation. We strive to enhance any gaps in maintenance strategies to ensure all factors from safety assurance to inspections are accounted for in the system, which will deliver the required asset availability or performance at the lowest overall cost, balancing maintenance cost with asset downtime costs.
RCM studies and facilitation
Set up of the base data and facilitation of the foundations required to build a maintenance program with reliability-centered maintenance principles. We use FMEA and FMECA cloud-based tools to run workshops, and face-to-face or remote sessions to evaluate the current applied maintenance.
Maintenance management system optimisation
This includes:
- Work order packaging, routing, and nesting
- Work order sequencing
- Work order smoothing and load-levelling
- Backlog rationalisation studies
Maintenance performance benchmarking
This includes:
- Third-party maintenance improvement studies
- Third-party CMMS data analysis and improvement recommendations
- Maintenance management KPI development and analysis
- Asset health check audit
Work execution support
This includes:
- Root cause analysis
- Maintenance management KPI analysis
- Backlog rationalisation studies
- Competency assessment
- Maintenance management training and coaching
- CMMS utilisation training
- Supply of maintenance management technical advisors and subject matter experts
- Supply of data scientists and CMMS analysts
Maintenance build and migration
New build plant
A full maintenance, integrity and materials management regime developed alongside the physical build to assure readiness for start-up.
Existing operational plant
An optimisation or rebuild of an existing maintenance, integrity and materials management regime to unlock efficiencies and ensure usability.
Plant upgrade and modifications
Replicate new equipment in the CMMS/EAM or ERP and apply the associated maintenance, integrity and materials management regime.
Plant life cycle management
Rationalisation and update of maintenance, integrity and materials management program to align to the phase in the asset’s operational life.
Acquisitions, mergers and new systems
To facilitate the migration and transfer of a maintenance, integrity and materials management regime from one, or multiple systems to another.
Assuring master data quality
To enable effective Data Management of Change (MoC) by monitoring your data to ensure it is maintained to the correct standards to avoid data quality drifts that undermine the proficiency of the CMMS/EAM or ERP.
Gain access to maintenance optimisation 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, minimise your exposure to risk or incident.
Minimise plant and equipment downtime
By mitigating identified failures through optimised equipment management strategies and execution plans, we can help minimise equipment outages and plant downtime.
Optimise operational and maintenance expenditure
Assuring the right maintenance is done at the right time, with the right materials, at an optimised frequency – no more no less, derived from independent experts.
Mitigate unhealthy maintenance backlog
Implement a fully optimised maintenance plan and schedule to maximise maintenance execution tactics and time available to liquidate work effectively.
Our maintenance optimisation software
Our award-winning software has been designed to improve the interface between people and data, harnessing machine learning and industry 4.0 to revolutionise the way businesses operate.
AssetVoice™
Automated change management and maintenance intelligence software
Asset Integrity Management case studies
“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 optimised levels of maintenance, done at the right time, in a globally consistent manner.”
Maintenance Director, International Energy Company
The 2023 Global Maintenance Manager Report
Produced by our Asset & Integrity Management specialists, this report features survey responses from hundreds of maintenance professionals from around the world as well as analysis and tips from industry experts.
Get in touch
By filling in the form below, you can speak to one of our experts to learn more about our solutions, request a quote or book a software demonstration.