{"id":58603,"date":"2024-01-12T11:31:00","date_gmt":"2024-01-12T11:31:00","guid":{"rendered":"https:\/\/abl-group.com\/abl\/?p=58603"},"modified":"2025-12-22T11:22:07","modified_gmt":"2025-12-22T11:22:07","slug":"achieving-safety-integrity-assurance-and-performance-excellence-through-a-data-driven-maintenance-improvement-project","status":"publish","type":"post","link":"https:\/\/abl-group.com\/abl\/all-media\/blog\/achieving-safety-integrity-assurance-and-performance-excellence-through-a-data-driven-maintenance-improvement-project\/","title":{"rendered":"Achieving safety\u00a0integrity assurance\u00a0and performance excellence through a data-driven maintenance\u00a0improvement project"},"content":{"rendered":"\n<p><strong>A high performing plant is one that is safe, efficient, reliable, and profitable and there are many critical success factors that come into play when it comes to striving for excellence.<\/strong><\/p>\n\n\n\n<p>The philosophies cascading into the management systems and processes influences all 4 elements of what it takes to be a high performer. Without a meticulously designed and executed CMMS resulting from this, 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.<br><br>To truly optimise a plant\u2019s maintenance and materials regime and unlock the associated benefits that come with it, it is key to build this regime using reliable, structured, and quality master data. Realising the need to have this in place, ABL were contracted by an international energy company 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&nbsp;<strong>1.3 million<\/strong>&nbsp;equipment tags.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-the-challenge\">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\u202fcomplete visibility\u202fof 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<h2 class=\"wp-block-heading\" id=\"h-what-we-did\">What we did<\/h2>\n\n\n\n<p>The ABL team was contracted to deliver the review, enrichment, and optimisation of their 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>\u202fto ascertain how critical the equipment\u2019s function is to the asset\u2019s production and safety integrity, to determine the optimal maintenance requirements\u202f<\/li>\n\n\n\n<li><strong>Equipment strategies:<\/strong>\u202futilising an <a href=\"https:\/\/abl-group.com\/abl\/case-studies\/fmea-development-and-facilitation-for-safety-and-production-critical-equipment-using-our-proprietary-effio-software\/\">FMECA based<\/a> approach and discovering existing pockets of maintenance excellence to apply learnings across assets, ensuring the optimum level of maintenance is assigned to equipment\u202fwhether that be assurance, preventative, predictive, or contingency<\/li>\n\n\n\n<li><strong>Equipment task lists:\u202f<\/strong>providing high-quality task lists, and a consistent approach to how maintenance is performed by the maintenance team\u202f<\/li>\n\n\n\n<li><strong>Equipment materials:<\/strong>\u202fpopulating the CMMS with the correct BoMs to ensure the right spares parts are identified to execute the maintenance\u202fwith consumable and contingency spares<\/li>\n\n\n\n<li><strong>CMMS implementation:<\/strong>&nbsp;Hassel free CMMS upload templates adhering to the change management process<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-the-result\">The result<\/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 company now has confidence that they are maintaining equipment at an optimum level and ensuring the risk profiles are still being managed.\u202f<br><br>Plant reliability and safety integrity of their facilities are of the most noticeable outputs of this project; not only are they setting record reliability statistics, but they are achieving this with optimised levels of maintenance, done at the right time, in a globally consistent manner.<br><br>As a by-product of the safety integrity and reliability benefits, this client also benefited from some significant cost savings, including:<\/p>\n\n\n\n<ul class=\"has-blue-color has-text-color has-link-color wp-block-list wp-elements-e1e125c8315af116451ca0dadee5fc3c\">\n<li>Savings of over\u202f<strong>$7M<\/strong>\u202fper year through the cleansing and net removal of\u202f<strong>210,000<\/strong>\u202ftags in CMMS that were duplicates or decommissioned equipment, additional critical tags were also added<\/li>\n\n\n\n<li>Savings of over\u202f<strong>$18.5M<\/strong>\u202fper year by rationalizing\u202f<strong>170,000<\/strong>\u202fannual planned maintenance hours\u202f<\/li>\n\n\n\n<li>Savings of\u202f<strong>$7M<\/strong>\u202fper year through optimization of annual planned maintenance work orders<\/li>\n\n\n\n<li>Savings of\u202f<strong>$14M<\/strong>\u202fon planning and efficiencies gains through enrichment of\u202f<strong>147,000<\/strong>\u202fMaintenance BoMs<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-about-effio\">About Effio <\/h2>\n\n\n\n<p>ABL\u2019s maintenance optimisation software, Effio\u2122, was used to deliver this project in a controlled, collaborative, efficient and cost-effective manner.<\/p>\n\n\n\n<p>Utilising the tools FMEA facilitation and analysis functionality, the team were able to:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Visualise and interpret the data better to review the assets\u2019 function, how it fails, its functional failures, consequence of failure and probability of failure with ease<\/li>\n\n\n\n<li>Update critically allocation in a standardised and systematic fashion<\/li>\n\n\n\n<li>Provide the client with logins to ensure technical authorities were able to attend workshops, review data and sign off on updates in a fully informed and efficient manner<\/li>\n<\/ul>\n\n\n\n<div class=\"wp-block-buttons is-layout-flex wp-block-buttons-is-layout-flex\">\n<div class=\"wp-block-button\"><a class=\"wp-block-button__link has-blue-background-color has-background wp-element-button\" href=\"https:\/\/abl-group.com\/abl\/effio\/\" target=\"_blank\" rel=\"noreferrer noopener\">learn more about effio<\/a><\/div>\n<\/div>\n\n\n\n<div style=\"height:31px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<figure class=\"wp-block-image size-large\"><a href=\"https:\/\/abl-group.com\/abl\/effio\/\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"668\" src=\"https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/03\/Effio-screens-2-1-1024x668.jpg\" alt=\"\" class=\"wp-image-58383\" srcset=\"https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/03\/Effio-screens-2-1-1024x668.jpg 1024w, https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/03\/Effio-screens-2-1-300x196.jpg 300w, https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/03\/Effio-screens-2-1-768x501.jpg 768w, https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/03\/Effio-screens-2-1-1536x1001.jpg 1536w, https:\/\/abl-group.com\/abl\/wp-content\/uploads\/2024\/03\/Effio-screens-2-1-2048x1335.jpg 2048w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/a><\/figure>\n","protected":false},"excerpt":{"rendered":"<p>To truly optimise a plant\u2019s maintenance and materials regime and unlock the associated benefits that come with it, it is key to build this regime using reliable, structured, and quality master data.<\/p>\n","protected":false},"author":20,"featured_media":57382,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"inline_featured_image":false,"footnotes":""},"categories":[6],"tags":[],"sector":[959,960],"service":[955,957],"company":[724],"class_list":["post-58603","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-blog","sector-asset-integrity-management","sector-software","service-asset-and-integrity-management","service-software","company-abl"],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v23.6 (Yoast SEO v27.3) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>Achieving safety\u00a0integrity assurance\u00a0and performance excellence through a data-driven maintenance\u00a0improvement project - ABL<\/title>\n<meta name=\"description\" content=\"To truly optimise a plant\u2019s maintenance and materials regime it is key to 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