Development of an asset management and maintenance program
The challenge
- A lack of maintenance history was available across all assets, causing difficulties in identifying opportunities to improve reliability
- Relying on poorly populated OEM maintenance strategies that did not account for the operating environment or take crew capabilities into consideration
- The CMMS (SAP) was missing core asset register data which was required to manage the assets effectively
- A lack of quality maintenance procedures
- Poorly implemented performance standard assurance tasks into the maintenance regime, exposing the asset to increased risk
- Inefficient maintenance planning and scheduling
What we did
To address the known issues affecting the effectiveness of the asset management and maintenance program, ABL conducted the following work tasks:
- Physical asset verification (PAV) of each drilling rig, covering over 6000 functional locations (tags)
- Update and enrichment of the asset register
- Criticality assessment and update
- Preventative maintenance benchmarking exercise, using ABL’s maintenance library to determine opportunities to optimize maintenance
- Embedment of assurance tasks into the preventative maintenance schedule
- Creation of Bill of Materials (BoMs) for high critical equipment
- Packaging, suppression, routing, and load leveling of the maintenance schedule with newly updated preventative maintenance work orders
What we found during the project
- 42% of the tags were missing from the asset register
- Inaccurate criticality rankings, including high critical equipment being identified as low critical and insufficient maintenance being assigned
- 0% of the equipment had BoMs assigned causing difficulties in identifying the right spare parts for maintenance or failures
- Missing critical maintenance work orders for high critical equipment
- Lack of quality maintenance procedures
- A high maintenance burden which was deemed unachievable and unrealistic to execute with the existing maintenance resources available
- A highly inefficient maintenance schedule with a lack of packaging, suppression, routing, and load leveling
- Assurance tasks were missing from the maintenance and inspection program
The value we delivered
An accurate and enriched asset register: The client now has assurance that what is on site is reflected accurately in the CMMS and can therefore be managed appropriately to mitigate risk, assure reliability, and optimize costs
SCE management and assurance: Safety critical elements are being managed appropriately to mitigate risk and assure compliance with performance standards and legislation
Optimised preventative maintenance regime: The ability to increase reliability through optimized preventative maintenance, enabling the asset team to intervene at the right time, to avoid known failure modes
Accurate spare part data for maintenance and failure: The BoMs delivered will help reduce equipment downtime, maintenance backlog and ensure the right spares are purchased to avoid unnecessary expenditure
Reduced equipment outage time: Reducing the requirement to take equipment offline multiple times through the optimization of the maintenance schedule (packaging, suppression, routing, and load leveling)
Boosted productivity: Through optimal usage of valuable resources and time, achieved through an optimised preventative maintenance schedule, assuring the right maintenance was done at the right time, with the right materials, no more no less
Software used to deliver the project
ePAV™
A data collection tool used for the PAV, designed to reduce time by and improve accuracy when verifying and collecting equipment data
Effio™
A CMMS build software offering a faster, more efficient, and effective way to manage and update maintenance and materials data
Maintenance strategy library
A comprehensive library of best-in-class maintenance strategies and procedures designed to facilitate the process of maintenance strategy creation or update