Development of Maintenance Strategies for Food Grade Oil Facility
Type:
Maintenance Strategy Optimisation
Client:
The food oil facility was in the final stages of construction and entering the commissioning phase. The company had selected Maximo as its Computerised Maintenance Management System (CMMS) and required the development of a complete set of maintenance strategies for integration and upload into the system to support operational readiness.
A project timeline was developed and agreed upon with the site team, outlining the following key phases:
- Project initiation, including training
- Criticality analysis
- FMECA and maintenance strategy development
- Condition monitoring assessment
- Site lubrication plan
- Maximo upload preparation
- Planning and scheduling workflow
Data was collected from the OEMs and entered into the FMECA worksheets. The on-site teams then reviewed and challenged the proposed strategies, providing valuable feedback for potential improvements.
A critical component of the new strategy was ensuring that appropriate condition-based monitoring (CBM) techniques were applied to the site’s most critical assets. A survey was conducted to assess which CBM methods were best suited for inclusion in the overall asset strategy.
CBM training was delivered to the team, and the necessary monitoring equipment was procured for in-house use. Another important focus area was the development of the site lubrication plan. A technician was appointed as the lubrication lead and successfully completed the ICML MLA I certification to support the site’s lubrication programme.
To enable effective execution of the strategy, a planning and scheduling workflow was also developed. This was captured in a Business Process Map that clearly defined the roles and responsibilities involved in planning, ensuring alignment across the team.
Key Findings:
The study was completed in 62 days and resulted in the analysis of
- 262 Equipment Items
- 1961 Failure modes identified
- 1996 maintenance tasks
- 91% of the tasks identified were
- Inspections (visual, CBM activity)
- 9% of the tasks identified were
- Preventative (clean, lubricate replace)
Conclusion:
As the plant transitions into full operation, it is expected that new operational data will become available. This data will be instrumental in further optimising the maintenance strategies. Ongoing analysis of failure history will be essential to ensure continuous improvement and long-term asset reliability.
We requested the services of Gary Tyne of Pro-Reliability Solutions to facilitate and lead the implementation of a best in class maintenance and reliability programme at the plant, given it being a single source of supply in the UK and the need to maintain our customer supply chain security throughout the operational year.
We would highly recommend Pro-Reliability Solutions for any other businesses considering such an implementation. Gary took a brand-new team, brand new facility and delivered this best in class programme over a 6-month period. His professionalism, subject knowledge and people skills have added significant value to the start-up of the factory and the development of our new team. He has also managed to do this coming in with very little process and commercial knowledge of our sector.
Group Operations Director
