Challenge

The client’s objective was to improve profit margins by developing and implementing a targeted reliability program that minimizes downtime and maximizes equipment performance. This program focused on proactive maintenance strategies, data-driven decision-making, and optimizing asset utilization. By enhancing operational efficiency and reducing unplanned outages, we aimed to lower costs and increase overall productivity.

Solution

A Valdes Architecture & Engineering staff member completed an initial assessment of the site to determine areas that needed to be developed for improved reliability. A Reliability Steering Committee was established, chaired by the Operations Manager, with the Maintenance and Engineering Managers serving as core members. A reliability incident investigation lead was appointed, and work processes were implemented to ensure the learnings from incidents were captured and shared across the site within four weeks.

Condition monitoring and operator & technician rounds were put in place to identify and address early signs of anomalies. Equipment critical to production was identified; actual and potential availability events ranked and vulnerabilities to production also identified. Reliability work processes were included in all new projects to stop defects from being introduced into the plant. Additionally, a sustainable defect elimination program with a ring-fenced budget was also implemented.

Impact

The facility’s availability began to increase within 24 months, with availability events dropping from 47 down to six per month, margins increasing by over 10%, and costs reducing by over 30% compared to the year when the program was launched.

Services

Maintenance, Reliability & Asset Integrity