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Maintenance Review and Improvement Strategy

Client: Chemicals Producer

Asset: Olefins & Polymers production plant

Project Objective: To review the client’s existing CMMS (SAP) data and recommend improvement opportunities designed to optimise the client’s maintenance management regime through enrichment of the master data, better utilisation of SAP functionality and optimisation of maintenance and materials allocation.

Location: Europe

Duration: 3 weeks

Software used

ABL’s CMMS data analysis and management software, Effio™ was used by the project team to deliver this project:


Effio™ is a cloud-based tool that can replicate our clients CMMS environment and provides a user friendly, collaborative, and accessible platform for analysing and enriching CMMS data, assigning criticality and allocating maintenance and materials to equipment tags efficiently, consistently, and accurately.

The challenge

As an existing operating production plant built over 20 years ago, the accuracy and completeness of the CMMS data required to manage the plants maintenance, integrity, and materials was inaccurate, unstructured, and missing critical data points.

The client’s objectives

  • To obtain a quantification of the missing and inaccurate data to understand the extend of the issues and justify a budget to fix the data concerns
  • To upgrade their existing plant work management system after recognising that the CMMS (SAP) functionality was not being utilised to its full capacity
  • To assure efficient use of the maintenance teams time and materials
  • To have accurate criticality rankings allocated to equipment to correctly prioritise maintenance and spares decisions
  • To assign maintenance work orders at an equipment level to allow for future analysis and optimisation of bad actors
  • To assign spare parts (Bill of Materials – BoMs) to tagged equipment and link them to maintenance tasks
  • To hold the optimised level of spare parts in stock to assure critical spares are available on demand and avoid overstocking and wasted expenditure

What we did

  • Extracted a sample of SAP data into our CMMS data build, analysis, and management software – Effio™
  • Conducted an initial review of the master base data, maintenance allocation and materials assignment
  • Reviewed the functional location hierarchy (asset register) and extracted data from P&IDs to determine accuracy
  • Facilitated an interactive criticality workshop using Effio™ to determine criticality, log decisions and determine rulesets for future allocation
  • Analysed the maintenance and materials allocation within the sample data set
  • Identified maintenance and materials optimisation improvements opportunities for where we identified discrepancies against best practice
  • Reviewed how the maintenance team were utilizing the functionality of the SAP system and the structure of the dataset
  • Conducted a cost benefit analysis to determine the projected value of the improvement’s vs effort required to make the changes proposed
  • Facilitated a final workshop to deliver the proposed improvement actions and roadmap based on the projected return on investment (ROI)

Project benefits

Understanding of data gaps

A clear understanding of where the data gaps existed in the CMMS and where to spend time and effort on enrichment of data for the most ROI

Clarity of data dependencies

Helped the client gain a clearer understanding of how to determine criticality effectively and the impact this has on the management of their plant

Value realisation

Identified where to implement low effort and high value improvements and when to use tactics such as RCM to maximise investments and ROI

Optimised budget

Justified where the client should focus their budget by improving the data, functionality of their CMMS and identifying where inefficiencies existed

The means to minimise downtime

Through advice on how to link materials/spare parts to equipment tags and maintenance, this will ensure critical spares are available on demand and help the client avoid overstocking and wasted expenditure

Established strategy

Improved the maintenance team’s awareness of the maintenance optimisation tactics available to them through a third party review

The value we delivered

CMMS data and utilisation improvement roadmap

An actionable and prioritised improvement roadmap, benchmarked against industry best practice and recommended by subject matter expert consultants and CMMS data analysts

Criticality allocation blueprint

Developed criticality rulesets and allocation guidance for efficient and effective equipment type assignment and criticality assessment and allocation

A cross party agreed optimisation path

Through the delivery of two remote workshops facilitated by ABL consultants, a clear optimisation decision was able to be made and mutually agreed, providing clear direction and buy in for the key stakeholders involved

Maintenance Strategy Optimisation

At ABL, we utilise our award-winning software, world-class maintenance standards and highly experienced experts to identify and implement maintenance optimisation tactics designed to safeguard production and minimise operational expenditure.