Real challenges, structured answers.

Challenge

In process industry with high availability demands, poorly structured maintenance programmes can lead to unnecessary inspections, recurring failures and unplanned production stops. There is often room to better match maintenance to equipment condition, failure history and criticality.

Approach

A review of existing maintenance plans and routines, focused on developing more proactive, risk-based maintenance.

• Evaluating and optimising preventive maintenance tasks
• Identifying equipment where condition-based maintenance gives better decision support
• Adjusting inspection intervals and tasks to actual equipment needs
• Developing standardised routines together with maintenance and operations staff
• Setting up a structure for follow-up and continuous improvement

Expected value

More needs-based maintenance, better use of resources and a better chance of detecting deviations before they lead to failures or disturbances.

Challenge

A maintenance system creates the most value when asset data, maintenance plans and work orders are structured consistently. Poor data quality and unclear processes make planning, follow-up and analysis harder.

Approach

Improving system support in IBM Maximo and creating a clearer link between maintenance strategy and daily work.

• Reviewing and quality-assuring the asset structure and equipment register
• Optimising preventive maintenance and related job plans
• Standardising work orders and maintenance activities
• Developing routines for recording failures, actions and history
• Anchoring shared ways of working with planners, technicians and users
• Using maintenance data as a basis for follow-up and decisions

Expected value

Better data quality, more consistent use of the maintenance system and a stronger basis for planning, analysis and long-term strategy development.

Challenge

Recurring equipment failures affect production, maintenance cost and the working environment. At the same time, the maintenance organisation needs to know which assets deserve the most attention and which actions have the greatest effect.

Approach

Combining criticality ranking with structured root cause analysis to give a clearer basis for maintenance priorities.

• Classifying equipment by consequences for production, safety, environment and cost
• Identifying critical assets and prioritising improvement areas
• Root cause analysis of recurring or significant failures
• Analysing underlying technical and organisational causes
• Defining corrective actions and improved maintenance strategies
• Working with operations and maintenance staff to anchor new routines

Expected value

Clearer prioritisation of maintenance resources, better understanding of failure mechanisms and a more systematic way of preventing recurring problems.