MaxGrip reduced man-hours for inspection and maintenance from 81.000 hours to 18.000 hours – calculated over 12 years. The estimated cost reduction was $848K per year on man-hours alone for the upcoming 12 years. Potential financial benefits are estimated to be higher, as the $850k savings per year only takes into account planned downtime, and not cost savings gained by reducing unplanned downtime through effective risk mitigation because of RBI. According to the client: “The project was fast paced and was handled very well by the MaxGrip personnel. Reporting to us was well presented and on time. The skills and expertise of the MaxGrip consultants were suitable to the project. They kept the pressure on delivery, making sure the project was completed on time.”
The output of the workshops enabled the client to stretch the inspection interval for 75% of the equipment (>900 FLOC’s), sometimes even with 3 times the current fixed interval, based on solid inspection data and/or a tangible risk-based approach. The items for which risk could not be mitigated further, an on-site critical spare was identified hence limiting the operational downtime when technical failure would inevitably occur.
MaxGrip also developed a RBI dashboard per production facility with 6 KPIs to make the result visible in one clear overview. This dashboard shows the current risks – allowing the client to focus on mitigating risks and extend inspection intervals even further.