+44 (0)20 7264 3250

Casualty Response

Get emergency support now


Maintenance Benchmarking and Optimisation Study

Client: Onshore Gas Plant

Duration: 2 months

Project Objective: To rationalise the maintenance expenditure through a strategic roadmap for optimisation and reduction of maintenance, whilst assuring the integrity of equipment

Location: Caspian Sea

Challenges faced by the client

Below is a summary of the challenges that the client faced prior to engaging with ABL:

  • Maintenance expenditure was extremely high
  • Corrective maintenance ratios were higher than planned
  • Significant reliability issues in relation to the equipment across multiple assets

How we helped

We analysed the client’s 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:

  • Data collection and review
  • Maintenance benchmarking
  • Engineering analysis and interpretation
  • Peer review with subject matter expert maintenance consultants
  • Identification of improvements
  • Impact assessment
  • Delivery of improvement roadmap based on ROI, effort and risk

Initial findings

  • Extreme differences in application of maintenance frequencies and activity types across units
  • High number of PMs were unnecessary and too frequent
  • Disproportionate planned hours in task lists
  • No use of failure codes in failure reporting
  • High proportion of maintenance short text was wrongly allocated to equipment
  • SCEs with no PMs allocated
  • High percentage of maintenance recorded against locations had no object types



Saved in 6 months by removing unnecessary PMs

Saved in 1 year by rationalising PMs and optimising frequencies

Safety critical equipment now have PMs assigned