{"id":57316,"date":"2020-07-24T13:37:00","date_gmt":"2020-07-24T12:37:00","guid":{"rendered":"https:\/\/abl-group.com\/abl\/?post_type=case-study&#038;p=57316"},"modified":"2024-09-17T15:28:40","modified_gmt":"2024-09-17T14:28:40","slug":"maintenance-benchmarking-and-optimisation-study","status":"publish","type":"case-study","link":"https:\/\/abl-group.com\/abl\/case-studies\/maintenance-benchmarking-and-optimisation-study\/","title":{"rendered":"Maintenance Benchmarking and Optimisation Study"},"content":{"rendered":"\n<div class=\"wp-block-cover alignfull has-parallax\"><span aria-hidden=\"true\" class=\"wp-block-cover__background has-blue-background-color has-background-dim-80 has-background-dim\"><\/span><div class=\"wp-block-cover__image-background wp-image-57318 has-parallax\" style=\"background-position:50% 50%;background-image:url(https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/02\/Key_Image-copy15-scaled.jpg)\"><\/div><div class=\"wp-block-cover__inner-container is-layout-constrained wp-block-cover-is-layout-constrained\">\n<p><strong>Client:<\/strong> Onshore Gas Plant<\/p>\n\n\n\n<p><strong>Duration:<\/strong> 2 months<\/p>\n\n\n\n<p><strong>Project Objective:<\/strong> To rationalise the maintenance expenditure through a strategic roadmap for optimisation and reduction of maintenance, whilst assuring the integrity of equipment<\/p>\n\n\n\n<p><strong>Location:<\/strong> Caspian Sea<\/p>\n<\/div><\/div>\n\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-challenges-faced-by-the-client\">Challenges faced by the client<\/h2>\n\n\n\n<p>Below is a summary of the challenges that the client faced prior to engaging with ABL:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Maintenance expenditure was extremely high<\/li>\n\n\n\n<li>Corrective maintenance ratios were higher than planned<\/li>\n\n\n\n<li>Significant reliability issues in relation to the equipment across multiple assets<\/li>\n<\/ul>\n\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-how-we-helped\">How we helped<\/h2>\n\n\n\n<p>We analysed the client\u2019s 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:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Data collection and review<\/li>\n\n\n\n<li>Maintenance benchmarking<\/li>\n\n\n\n<li>Engineering analysis and interpretation<\/li>\n\n\n\n<li>Peer review with subject matter expert maintenance consultants<\/li>\n\n\n\n<li>Identification of improvements<\/li>\n\n\n\n<li>Impact assessment<\/li>\n\n\n\n<li>Delivery of improvement roadmap based on ROI, effort and risk<\/li>\n<\/ul>\n\n\n\n<div style=\"height:50px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-cover alignfull is-light\"><span aria-hidden=\"true\" class=\"wp-block-cover__background has-blue-background-color has-background-dim-0 has-background-dim\"><\/span><div class=\"wp-block-cover__inner-container is-layout-constrained wp-block-cover-is-layout-constrained\">\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\">\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"545\" src=\"https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/02\/AL_Maintenance_Benchmarking_and_Optimisation_Study_Key_Image3-1024x545.jpg\" alt=\"\" class=\"wp-image-57323\" srcset=\"https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/02\/AL_Maintenance_Benchmarking_and_Optimisation_Study_Key_Image3-1024x545.jpg 1024w, https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/02\/AL_Maintenance_Benchmarking_and_Optimisation_Study_Key_Image3-300x160.jpg 300w, https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/02\/AL_Maintenance_Benchmarking_and_Optimisation_Study_Key_Image3-768x409.jpg 768w, https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/02\/AL_Maintenance_Benchmarking_and_Optimisation_Study_Key_Image3-1536x818.jpg 1536w, https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/02\/AL_Maintenance_Benchmarking_and_Optimisation_Study_Key_Image3-2048x1090.jpg 2048w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\">\n<h2 class=\"wp-block-heading\" id=\"h-initial-findings\">Initial findings<\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Extreme differences in application of maintenance frequencies and activity types across units<\/li>\n\n\n\n<li>High number of PMs were unnecessary and too frequent<\/li>\n\n\n\n<li>Disproportionate planned hours in task lists<\/li>\n\n\n\n<li>No use of failure codes in failure reporting<\/li>\n\n\n\n<li>High proportion of maintenance short text was wrongly allocated to equipment<\/li>\n\n\n\n<li>SCEs with no PMs allocated<\/li>\n\n\n\n<li>High percentage of maintenance recorded against locations had no object types<\/li>\n<\/ul>\n<\/div>\n<\/div>\n<\/div><\/div>\n\n\n\n<div class=\"wp-block-cover alignfull has-parallax\"><span aria-hidden=\"true\" class=\"wp-block-cover__background has-blue-background-color has-background-dim-80 has-background-dim\"><\/span><div class=\"wp-block-cover__image-background wp-image-57306 has-parallax\" style=\"background-position:50% 50%;background-image:url(https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/02\/AL_Image_Software_AimHi_Screenshot_Mockup_v2.jpg)\"><\/div><div class=\"wp-block-cover__inner-container is-layout-constrained wp-block-cover-is-layout-constrained\">\n<h2 class=\"wp-block-heading has-text-align-center has-large-font-size\" id=\"h-results\"><strong>Results<\/strong><\/h2>\n\n\n\n<div class=\"wp-block-columns are-vertically-aligned-top is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-vertically-aligned-top has-teal-color has-text-color is-layout-flow wp-block-column-is-layout-flow\">\n<p class=\"has-text-align-center countup has-teal-color has-text-color\" style=\"font-size:50px\"><strong>41<\/strong><\/p>\n\n\n\n<p class=\"has-text-align-center has-text-color has-link-color has-small-font-size wp-elements-3e5aa1bb77a4ab87341eed448cff6705\" style=\"color:#ffffff\">Improvement changes identified<\/p>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-top is-layout-flow wp-block-column-is-layout-flow\">\n<p class=\"has-text-align-center countup has-teal-color has-text-color has-link-color wp-elements-c9a60b0dfa670d924812801c265ece2f\" style=\"font-size:50px\"><strong>$7.1m<\/strong><\/p>\n\n\n\n<p class=\"has-text-align-center has-small-font-size\">Saved in 6 months by removing unnecessary PMs<\/p>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-top is-layout-flow wp-block-column-is-layout-flow\">\n<p class=\"has-text-align-center countup has-teal-color has-text-color has-link-color wp-elements-d5fec34686d0b62b0006efa4f66c7b03\" style=\"font-size:50px\"><strong>$20m<\/strong><\/p>\n\n\n\n<p class=\"has-text-align-center has-small-font-size\">Saved in 1 year by rationalising PMs and optimising frequencies<\/p>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-vertically-aligned-top is-layout-flow wp-block-column-is-layout-flow\">\n<p class=\"has-text-align-center countup has-teal-color has-text-color has-link-color wp-elements-d5f47556e660dfb9c2e4cc8c534a962a\" style=\"font-size:50px\"><strong>PMs<\/strong><\/p>\n\n\n\n<p class=\"has-text-align-center has-small-font-size\">Safety critical equipment now have PMs assigned<\/p>\n<\/div>\n<\/div>\n<\/div><\/div>\n\n\n\n<div style=\"height:35px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-buttons is-content-justification-center is-layout-flex wp-container-core-buttons-is-layout-16018d1d wp-block-buttons-is-layout-flex\">\n<div class=\"wp-block-button has-custom-font-size has-medium-font-size\"><a class=\"wp-block-button__link has-blue-background-color has-background wp-element-button\" href=\"https:\/\/abl-group.com\/abl\/consulting-and-engineering\/asset-and-integrity-management\/benchmarking-and-analysis\/\">Learn more about our benchmarking solutions<\/a><\/div>\n<\/div>\n\n\n\n<div style=\"height:100px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n","protected":false},"author":25,"featured_media":58370,"template":"","sector":[959,960],"service":[955,957],"company":[],"class_list":["post-57316","case-study","type-case-study","status-publish","has-post-thumbnail","hentry","sector-asset-integrity-management","sector-software","service-asset-and-integrity-management","service-software"],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v23.6 (Yoast SEO v27.4) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>Maintenance Benchmarking and Optimisation Study - ABL<\/title>\n<meta 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