Deploying Efficient and Lean Maintenance Model by Optimization and Standardization of Companywide Maintenance Job Plans and Resources Adopting a Centralized and Unified Approach

Abstract As part of our continuous efforts to foster uniformity, efficiency, compliance to best practices and standardization, a new systematic initiative was taken to standardize and optimize the maintenance job plans and resources (logistics and manpower) for three maintenance disciplines (Mechanical, Electrical & Instrument) across company sites to ensure optimal number of personnel required for a defined set of maintenance activities. We conducted an initial review and analysis of the maintenance plans across company sites and found discrepancies and different practices implemented. Potential opportunities were also identified which could be utilized to obtain lean and standardized maintenance programs across company sites. Thus, SMEs from different disciplines conducted deep dive reviews and brainstorming sessions to reach an optimal maintenance program that can be implemented without compromising HSE and asset integrity. It was also observed that there was no systematic and standardized practice being followed to quantify the required maintenance resources (manpower and logistics) and to validate the forecasted manpower for business plan. The outcome of maintenance job plan standardization exercise was later applied to validate the manpower requirement (existing as well as 5 / 10-Year business plan) and thus achieving significant optimization.