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A goal of 80% planned maintenance is attainable when a plant asset management platform is integrated with maintenance strategy during engineering design.

A goal of 80% planned maintenance is attainable when a plant asset management platform is integrated with maintenance strategy during engineering design.

After speaking directly with more than 600 process industry maintenance supervisors, key personnel, and plant process engineers over the past three years, it’s clear that most are engaged in a neverending struggle to reduce reactive (unplanned) maintenance, which consumes as much as 80% of the maintenance manhours in their plants. It’s no wonder they can’t achieve “bestcost producer” status—or even cut costs significantly. Their profits are eaten away by overtime labor costs and production losses due to unplanned maintenance activities.
The exceptions to this reactive maintenance cycle are people working in new facilities, where very little equipment breaks in the first two years. It is not until machinery begins to wear out after some years of heavy operation that the high costs of unexpected downtime and maintenance really hit home.
The best way to prevent such losses is to attack the problem long before it occurs, during the front end engineering and design (FEED) stage of a capital project. The foundation for a functional maintenance strategy capable of reducing life-cycle costs should be laid before the plant is built.
Plants without a viable maintenance strategy will not be able to sustain the high new-plant reliability
they experience when they first go into operation.

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