img img img img

Consulting

Our team has rich experience in

Maintenance and Reliability Maturity Assessments

Maintenance Performance Improvement Programs

Preventive Maintenance Optimization

Maintenance and Reliability Maturity Assessments

1. We observe maintenance activities, interview employees, review processes, documentation, analyse failure and maintenance data.
2. A comprehensive report is presented to the client company with clear picture of current state, strengths, weaknesses and where the company stands in comparison with industry average, best in class and world class.
3. We also provide a clear picture of opportunities and the measures the company can take for short and long term benefits.

Reliability and Maintenance Performance Improvement programs

We design and work with the plant core team to implement an effective maintenance performance improvement program at the site. This program is centered around implementing an effective maintenance planning and scheduling methodology as being practiced by world class companies. We modify the work management processes wherever necessary, create related documents and SOPs, provide training to the stakeholders, work with the planners and schedulers, monitor progress and ensure sustainability of the new practices.

End Results

Reduced Equipment Downtime

Up to 10% to 15% reduction in equipment downtime is
obtained within 1 year of successful implementation of
the project

Improved Equipment Reliability

Distinct improvement in equipment reliability is observed as the maintenance planning and scheduling practices gain maturity

Up to 100% increase in maintenance workforce productivity

The average wrench time in a reactive work culture is around 25% and lower. With successful implementation effective maintenance planning and scheduling, the wrench time gradually rises to 50% and more. The world class standard is 62%.

Optimized Spare Parts inventories

As the procurement and consumption of spares is
line with the look ahead maintenance schedule,
spares inventories get reduced.

Reduction in maintenance costs

Major continual reduction in maintenance costs is observed as more and more work gets planned and rightly scheduled. The cost reduction exceeds 10% during the 1st year of implementation.

Improved repair quality and plant safety

There is major improvement in Rework. Safety incidences and near misses get reduced as there is focus on safety aspect during planning. Reduction in emergencies result in further reduction in safety incidences.

Improved Work Relations Between Departments

All the maintenance work to be carried out is well known to all the stake holders well in advance. Hence there are few surprises. The weekly schedule is protected by the operations Head.

Improved work life balance

There are fewer emergencies and urgent work orders. Call outs get reduced.

Reliability and Maintenance Performance improvement program

We design and work with the plant core team to implement an effective maintenance performance improvement program at client sites. The improvement program is in close alignment with world class work management practices. It is centred around implementing  Effective Maintenance Planning and Scheduling  Preventive Maintenance Optimization  Defect elimination

img

Reduced equipment downtime

Planned and predictive maintenance helps minimize unplanned downtime, allowing operations to run more smoothly and efficiently.

Get Started
img

Improved inventory control

Reduction in overtime and contract labour Improved inventory control

Get Started
img

Improved maintenance

With our reliability and maintenance program you will see Improved

Get Started
img

Improved Equipment Reliability

Improved Equipment Reliability

Well-maintained equipment is less likely to experience unexpected breakdowns or failures, leading to increased uptime and productivity.
Get Started
img

Reduction in maintenance costs

Lower maintenance costs directly contribute to higher profit margins, as less money is spent on repairs and upkeep.

Get Started
img

Improved repair quality and plant safety

Improved plant safety measures and high-quality repairs can significantly reduce the likelihood of accidents and injuries among employees, creating a safer work environment.

Get Started
img

Improved employee moral

A well-maintained work environment can contribute to a more positive and motivated workforce, as employees are less likely to be frustrated by equipment failures.

Get Started

Preventive Maintenance Optimization-PMO

Preventive Maintenance Optimization often referred to as PMO is the process of identifying and eliminating the wastes in your existing PM program. PMO ensures that each of the maintenance tasks performed during a PM are directed towards preventing the related potential failures. A poorly designed PM program not only results in wastages of resources in the form of manpower and material, but also causes more equipment failures rather than preventing the failures. Studies have proved that up to 40% reduction in PM maintenance cost can be achieved through continuous PMO exercises. We as Subject Matter Experts in this key area help companies to successfully develop and implement PMO at their sites.

Do you have any question? Feel free to contact us.

Open chat
Hello 👋
Can we help you?