A refining facility, designed to selectively remove and refine valuable metals, was shut down following only 18 months online. A run-to-failure facility maintenance strategy and underutilized computer maintenance management system [CMMS] – together with a “maintain production at all costs” mandate – resulted in:
- Catastrophic equipment failure
- Damage due to undesirable and unsafe maintenance practices
- Negative environmental impact
- Ultimately, plant bankruptcy
A new in-house management team was created and an engineering procurement construction management [EPCM] company was brought in to address the main engineering challenges. A feasibility study was conducted, and a holistic review of the management systems was performed; a key item identified for overhaul and upgrade was the CMMS.
ARMS Reliability was brought in to assess issues with the site’s current maintenance strategy and systems to fully understand the current situation.
We discovered that the plant’s CMMS setup was severely limited and unable to deliver useful information. For example, it lacked a consistent naming convention – ‘assets’ were frequently referred to as ‘systems’ and vice versa, some assets were listed multiple times, the hierarchy was unstructured so that assets and systems existed at the same level, and there was an excessive dependence on ‘default equipment’ as a category.
ARMS Reliability’s work provided our client with a fully developed maintenance strategy implemented into the CMMS. This optimized strategy has allowed the plant to prepare to re-launch operations with a detailed, accurate system designed to proactively prevent performance failure. Our team-based approach engages site staff in the development and implementation process, promoting understanding and buy-in, and ensuring the continued success of the new maintenance strategy.
Our OnePM® software platform facilitated all phases of the maintenance strategy development and proved especially valuable during the implementation of the strategy in to the CMMS. OnePM® dramatically increased the speed at which the new maintenance hierarchy could be developed and new strategies deployed throughout the plant, to all 6,500+ assets; the implementation was completed with an estimated time-savings of around 80% over other methods that don’t have the scalability of OnePM®. Additionally, using OnePM®, the company could leverage the data gathered at this plant to improve performance at other similar facilities.
Using the newly developed maintenance strategy with the CMMS, our client can now deliver and sustain performance at their refinery – and do so with a new understanding of how effective maintenance strategies support and enhance the sustainability of the company as a whole. ARMS Reliability will continue its partnership with this client to continue to improve performance; long-term objectives include further refinement of maintenance metrics, introduction of a defect elimination process, and movement toward more predictive technologies.