{"id":57368,"date":"2021-08-26T16:12:00","date_gmt":"2021-08-26T15:12:00","guid":{"rendered":"https:\/\/abl-group.com\/abl\/?post_type=case-study&#038;p=57368"},"modified":"2024-07-02T11:28:57","modified_gmt":"2024-07-02T10:28:57","slug":"global-maintenance-build-and-strategy-optimisation","status":"publish","type":"case-study","link":"https:\/\/abl-group.com\/abl\/case-studies\/global-maintenance-build-and-strategy-optimisation\/","title":{"rendered":"Global maintenance build and strategy optimisation"},"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-70 has-background-dim\"><\/span><div class=\"wp-block-cover__image-background wp-image-57371 has-parallax\" style=\"background-position:50% 50%;background-image:url(https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/02\/Credentials-images-ASPAC-1-1.png)\"><\/div><div class=\"wp-block-cover__inner-container is-layout-constrained wp-block-cover-is-layout-constrained\">\n<p><strong>Project Objective:<\/strong> To achieve safety integrity assurance and performance excellence through a data-driven maintenance improvement project.<\/p>\n\n\n\n<p><strong>Client:<\/strong> Oil and Gas Operator<\/p>\n\n\n\n<p><strong>Asset:<\/strong> 30+ onshore and offshore production facilities<\/p>\n\n\n\n<p><strong>Duration: <\/strong>4 years<\/p>\n\n\n\n<p><strong>Location:<\/strong> Global<\/p>\n\n\n\n<p><strong>Software:<\/strong> <a href=\"https:\/\/addenergy.no\/software\/asset-management-strategy-deployment-and-optimization-software\/effio\">Effio\u2122<\/a><\/p>\n<\/div><\/div>\n\n\n\n<div style=\"height:35px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-project-synopsis\">Project synopsis<\/h2>\n\n\n\n<p>Without a meticulously designed and executed maintenance management regime, plants are subject to increased risk of equipment failure, loss of production, and excessive maintenance costs \u2013 which will directly impact the safety integrity and performance of the plant.<\/p>\n\n\n\n<p>To truly optimise the client\u2019s maintenance and materials regime and unlock the associated benefits that come with it, it was key to build this regime using reliable, structured, and quality master data. Realising the need to have this in place, ABL was contracted to deliver a global maintenance optimisation project where we were tasked with enriching the CMMS data and optimising the maintenance management regime, and associated spare parts in excess of 2 million equipment tags.<\/p>\n\n\n\n<div style=\"height:36px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">The challenge<\/h2>\n\n\n\n<p>To assure the right level of preventative and predictive maintenance and inspection, on the right equipment, was being done with the right materials, at the right time \u2013 no more, no less. Achieved through:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Having the means to operate safely, by having complete visibility of what equipment they have, how its classified and risk ranked, how and when it should be maintained, and the materials that are required to do this<\/li>\n\n\n\n<li>Applying best-in-class maintenance strategies at an optimum frequency to mitigate failure, reduce risk and optimise cost<\/li>\n\n\n\n<li>Consolidating the client\u2019s approach to maintenance and integrity management by migrating into one standardised global CMMS solution<\/li>\n<\/ul>\n\n\n\n<div style=\"height:35px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">What we did<\/h2>\n\n\n\n<p>The ABL team were contracted to deliver the review, enrichment, and optimisation of the client\u2019s global approach to maintenance and integrity management. This included:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Equipment identification:<\/strong>&nbsp;to ensure all equipment that requires maintenance was in the CMMS, by establishing and implementing the data standard<\/li>\n\n\n\n<li><strong>Equipment classification and criticality:<\/strong>&nbsp;to ascertain how critical the equipment\u2019s function is to the asset\u2019s production and safety integrity, to determine the optimal maintenance requirements<\/li>\n\n\n\n<li><strong>Equipment strategies:<\/strong>&nbsp;utilising an FMECA based approach and discovering existing pockets of maintenance excellence to apply learnings across assets, ensuring the optimum level of maintenance is assigned to equipment whether that be assurance, preventative, predictive, or contingency<\/li>\n\n\n\n<li><strong>Equipment task lists:<\/strong>&nbsp;providing high-quality task lists, and a consistent approach to how maintenance is performed by the maintenance team<\/li>\n\n\n\n<li><strong>Equipment materials:<\/strong>&nbsp;populating the CMMS with the correct BoMs to ensure the right spares parts are identified to execute the maintenance with consumable and contingency spares<\/li>\n\n\n\n<li><strong>CMMS implementation:<\/strong>&nbsp;Hassle free CMMS upload templates adhering to the change management process<\/li>\n<\/ul>\n\n\n\n<div style=\"height:35px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\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<h2 class=\"wp-block-heading\">The results<\/h2>\n\n\n\n<p>Having complete visibility of their equipment, and how important it is, has been instrumental in building the foundations for achieving maintenance excellence. The client now has confidence that they are maintaining equipment at an optimum level and ensuring the risk profiles are still being managed.<\/p>\n\n\n\n<p><strong>As a by-product to the safety integrity and reliability benefits, this client also benefited from some significant cost savings, including:<\/strong><\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Savings of over&nbsp;<strong>$9M<\/strong>&nbsp;per year through the cleansing and net removal of 290,000 tags in CMMS that were duplicates or decommissioned equipment, additional critical tags were also added<\/li>\n\n\n\n<li>Savings of over&nbsp;<strong>$21M<\/strong>&nbsp;per year by rationalising 198,000 annual planned maintenance hours<\/li>\n\n\n\n<li>Savings of&nbsp;<strong>$8.7M<\/strong>&nbsp;per year through optimisation of annual planned maintenance work orders<\/li>\n\n\n\n<li>Savings of&nbsp;<strong>$18M<\/strong>&nbsp;on planning and efficiencies gains through enrichment of 147,000 Maintenance BoMs<\/li>\n<\/ul>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\"><div class=\"wp-block-image\">\n<figure class=\"alignright size-large is-resized\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"667\" src=\"https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/02\/Our-results-graphics_global-maintenance-build-and-strategy-optimization-1024x667.jpg\" alt=\"\" class=\"wp-image-57369\" style=\"width:551px;height:auto\" srcset=\"https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/02\/Our-results-graphics_global-maintenance-build-and-strategy-optimization-1024x667.jpg 1024w, https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/02\/Our-results-graphics_global-maintenance-build-and-strategy-optimization-300x196.jpg 300w, https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/02\/Our-results-graphics_global-maintenance-build-and-strategy-optimization-768x501.jpg 768w, https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/02\/Our-results-graphics_global-maintenance-build-and-strategy-optimization.jpg 1080w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n<\/div><\/div>\n<\/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-cover alignfull has-parallax\" style=\"min-height:280px;aspect-ratio:unset;\"><span aria-hidden=\"true\" class=\"wp-block-cover__background has-blue-background-color has-background-dim-60 has-background-dim\"><\/span><div class=\"wp-block-cover__image-background wp-image-57370 has-parallax\" style=\"background-position:50% 50%;background-image:url(https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/02\/Credentials-images-ASPAC-1.png)\"><\/div><div class=\"wp-block-cover__inner-container is-layout-constrained wp-block-cover-is-layout-constrained\">\n<figure class=\"wp-block-pullquote has-medium-font-size\"><blockquote><p>\u201cPlant 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.\u201d<\/p><cite><em><small><em>Director of Maintenance, International Energy Producer<\/em><\/small><\/em><\/cite><\/blockquote><\/figure>\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\/maintenance-strategy-optimisation\/\">learn more about our maintenance optimisation solutions<\/a><\/div>\n<\/div>\n\n\n\n<div style=\"height:40px\" 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-lightgrey-background-color has-background-dim-30 has-background-dim\"><\/span><div class=\"wp-block-cover__inner-container is-layout-constrained wp-block-cover-is-layout-constrained\">\n<h2 class=\"wp-block-heading\" id=\"block-80c82369-9ba6-4831-ae52-50f0a1d77ffb\"><br>Get in touch<\/h2>\n\n\n\n<p id=\"block-5c00ae03-2405-4bea-86a2-e04b033691e4\">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.<\/p>\n\n\n\n<div class=\"wp-block-zoho-zoho-forms\"><div id=\"zf_div_Kn9sLtkIdJ6Ale8N1KllMDPqsl3R8M10dvBXDmFF51o\"><\/div>\r\n            <script type=\"text\/javascript\">\r\n                (function() {\r\n                    try{var f = 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