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Maintenance Strategy ALIGNMENT REVIEW

Does your plant maintenance equipment strategies need optimizing?

Is your plant maintenance equipment strategy library actually optimized to meet your specific equipment in each specific asset, or is it so generic that its not adding any value at all?

Don’t know? Are you experiencing:

  • Recurring problems with equipment
  • Budget blow-outs from costly fixes to broken equipment
  • Unplanned downtime that has a flow-on effect on production
  • Using equipment that is not performing at 100%
  • Risk of safety and environmental incidents
  • Risk of catastrophic failure and major events
  • Inconsistent failure rates of similar equipment across your asset and fleet.

 

If not, then allow Asset Integrity Group to run a maintenance strategy alignment study and we’ll optimize your planned maintenance to ensure accordance with ISO14224 and NORSOK Z-008, necessary as a minimum for high equipment uptime assurance.

 

Typical root causes for the points listed above are:

1. Consistently high unplanned maintenance

A sure sign that your maintenance strategy is not working is the simple fact that you are performing more unplanned maintenance, which is caused by your maintenance strategy having inadequate procedures in place to mitigate against all known failures. More specifically the failure mechanisms are not fully understood and as such the procedure needs to be optimized to work effectively. Simply put, if your planned maintenance was working properly then you’d have negligible corrective maintenance work orders spinning off the back of your planned maintenance tasks. Your maintenance strategies causing high rates of failure must be analysed from a reliability perspective and reworked.

 

2. Rising maintenance costs

In companies that apply best practice maintenance strategy optimization, total maintenance costs are flat or slightly decreasing month-on-month. These optimized strategies combine preventative tasks with various inspection and root cause elimination tasks which in turn produces the optimized cost solution.

 

3. Excessive variation in output

A simple definition of the reliability of any process is that it does the same thing every day. In other words, equipment should run at the desired design intent capacity day in and day out. When it doesn’t, this is an indication that some portion of the maintenance strategy is misaligned and not fully effective.

 

4. Strategy sticks to OEM recommendation

Sticking to the maintenance schedule prescribed by Original Equipment Manufacturers (OEMs) is a good starting point for brand new equipment – especially if still under warranty. After 2-3 years of operation then it is highly desirable to conduct a reliability study to see how effective the OEM maintenance is when operating within the specific asset environment, and dynamic experienced in situ. There are many reasons why you should create your own optimized maintenance strategy soon after implementation.

 

5. An inconsistent approach

Consistency implies lack of deviation. This requires standardization. When it comes to maintenance strategies, standardization of the same equipment classification type across your asset / fleet is paramount.

It’s imperative that your equipment classification codes have the correct granularity to allow specific maintenance work flows to be designated to specific equipment, that fully mitigates reoccurrence of failure. Applying the same maintenance task list to your granulized asset equipment then assures that consistency is being practiced across your fleet.

 

Let Asset Integrity Group analyse the maintenance alignment qualities across your fleet, where we cross correlate with achieved reliability figures and highlight exactly where your asset’s bad actors are and provide a list of specific equipment maintenance strategies that require optimizing.

ASSET INTEGRITY GROUP LTD

Company Number: SC532960

Copyright © Asset Integrity Group

(+44) 01224 958 656

info@assetintegrity.group

PLEASE GET IN TOUCH FOR MORE DETAILS ON HOW ASSET INTEGRITY GROUP’S TRUE FRAMEWORK CAN HELP YOUR HIGH-RISK ASSETS FUNCTION SAFELY AND LEGISLATIVELY, WHILE BEING PRODUCTION & COST EFFICIENT

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