Stage one: Fixing the basics. The project started with a review of the asset register, the safety-critical elements (SCEs), and a first benchmark and optimization of the preventive maintenance (PM) routines.
Stage two: Fully optimizing the maintenance build in the CMMS system, completing the workload levelling process, and aligning all tasks with updated maintenance strategies and performance standards.
The first stage alone resulted in savings of US$ 600,000 year on year on man hours only. Stage two, the actual PM optimization project, has also yielded very good results. By reducing the number and frequency of PM tasks, clustering and enriching them, the company was estimated to save over US$ 1.75 million year on year.