Success case ■

Oil & Gas

Optimization of the intervals of preventive maintenance

New interval of preventive maintenance calculated:

Replace the tool

years

Economy of

K$ / year

Compared to the current situation

years

Economy of

K$ / year

Compared to an interval of preventive maintenance more strengtthened :

Client's Needs

The interval of preventive maintenance of equipments is a problem for the client.
He follows the orientations of the manufacturer, replacing the equipment every 10 years
When noticing a level of the tool failure of 5% before 7 years, he wants to reconsider the intervals of preventive maintenance.
The restrictive conditions for the tooling maintenance are the following:
• Replacement cost : 470K€
• Intervention time : 10 days

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Assetsman's solution

Assetsman's team used its calculation algorithm* to:
• Value the cost of the current preventive maintenance task
• Define the interval of maintenance for the lower cost
• Value the gain between Assetsman's results and the current policy of the client

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Energy

Optimization of the spare parts or inventory management

Obtained economy with the new stock policy

Résultats

Client's needs

Policy of spare parts stock considered very conservative by the client.
He wants to implement an evaluation and optimization of the stock policy to obtain economy.
The study involves 45.000 spare parts, 3 power generating plants and 10 independet substations.
The stock policy currently is cautious, since the client has to assure the continuous supply of electricity and water.
The client's objective is to define which spare parts should be reduced, kept, or raised.

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Assetsman's solution

Assetsman's team used Assetsvalue to:
• Value the client's current stock in terms of cost and risk
• De fine a level of consented risk for the client
• Resize the stock based on this consented
• Define a new policy for spare parts stock
• Value the gain between Assetsman's results and the current policy of the client

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Paper and Pulp

Optimization of maintenance major shutdowns

Simulation of

Different preventive maintenance tasks

Planning

out of

shutdowns per year or 1 shutdown less per year

Economy of

% over the annual costs of the major shutdowns

Client's needs

The client wants to reduce the cost of annual maintenance major shutdowns at the lower risk.
Two cases to deal with regrouping 70 equipments of 4 different families.
The cost of the current major shutdowns is between 1 and 4 million euros (3 shutdowns / year).

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Assetsman's solution

Assetsman's team used to:
• Value precisely the cost of annual major shutdowns
• Determine for each task the right moment to be done
• Direct all tasks to a commom Optimum with the best trade-off risk / cost
• Value the gain between Assetsman's results adn the current policy of the client l

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Steel

Optimization of maintenance major shutdowns

Reduction of

% in the operations of maintenance control and review of TPM standards

Gains of

hours of workforce/year

Reduction of unavailability of equipments for preventive maintenance of around

hours

Client's needs

The equipment availability is considered inadequate by the client.
He wants to implement an approach to improve the availability of production equipments and, particularly to:
• Reduce failure rates
• Reduce recurrent malfunctions
• Reduce the periods of unavailability due to preventive maintenance

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Assetsman's solution

Assetsman's team used Assetsvalue to:
• Implement the method CBA (Core Business Analysis): identification of the equipments that obstruct reaching the availability objectives (bottlenecks)
• Carry out trainings of the methods RCM and RCA (over 100 people trained)
• Carry out pilot studies for relevant workshops
• Follow the teams as part of the development of the approach RC< and RCA in the plant

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Airports

Support for the preparation to the certification ISO 55001

Certification ISO 55001 obtained by the client in less than

years

Support to the teams

trained people

First economies
achieved thanks to
pilote studies

Client's needs

Concern with the image of brand and marketing communication with the interested parts and aviation professionals.
The client wants to show the efficient asset management to the regulatory authorities.
To do that he needs to create a system of asset management according to ISO 55001.
Stating the approach in the second semester of 2014.

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Assetsman's solution

Assetsman's team used its expertise on the standard ISO 55001 to:
• Carry out a diagnosis using the maturity scales provided by the IAMS method (interactive assessment for asset & maintenance strategies)
• Develop and implement a master plan of Asset Management
• Set up an asset management system
• Train and monitor teams (one hundred professionals trained)
• Carry out pilot studies (RCM/LCC…) that legitimize the appropriate beginning of the master plan and enable to get the first gains

Chemical Industry

Prioritization of investment projects according to the approach risk / cost

+ than

alternative scenarios proposed

Economy of

K€

increasing the limite of investment in

Investment Plan
optimized
according to the restrictions of annual investments

Client's needs

The client has 40 investments projects to carry out, half of them are considered urgent and with a high added-value.
Incapable of carrying them out immediately (annual budget restricted), the client needs an alternative investment plan in the next 5 years.
He wants to prioritize the investment projects (CAPEX) taking into account the trade-off between risks and costs.

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Assetsman's solution

Assetsman's team used its calculation algorithm to:
• Define the appropriate moment to carry out the investment projects (LCC)
• Determine the losses due to the anticipation or delay in the conclusion of the projects
• Elaborate different scenarios of investment to find the most appropriate one regarding to the client's needs (budget limits)
• Help the client choose the scenario according to the trade-off risk / cost