A leading U.S. energy company, managing a diverse portfolio of refineries and renewable diesel facilities, faced the challenge of aligning reliability practices amid rapid growth. With a larger fleet, more employees, and operations spanning multiple countries, the need for standardized maintenance strategies became critical.
A Partnership for Excellence
To address these challenges, the company partnered with MaxGrip and adopted Cenosco’s IMS Suite to implement a comprehensive Reliability Centered Maintenance (RCM) program. This initiative aimed to enhance operational efficiency, optimize maintenance processes, and foster a unified culture of sustainability and consistency across all sites.
Pilot: Laying the Groundwork
The initiative began with a pilot program at one refinery, focusing on critical systems and equipment. In just five weeks, the pilot analyzed 80 assets, producing actionable strategies and validating the scalability of the methodology. This “fail fast” approach allowed teams to refine processes quickly and gain buy-in from stakeholders, setting the stage for a full fleet-wide rollout.
Scaling Success Across the Fleet
Building on the pilot’s success, the company launched a structured three-year plan to implement the RCM program across six sites. The approach centered on three pillars:
- People: Multidisciplinary teams were equipped with training, coaching, and tools to ensure seamless adoption of the new practices.
- Processes: Automated workflows and data harmonization streamlined RCM analysis, reducing implementation time by 70%.
- Plant: A staggered rollout allowed for lessons learned at each site to be applied to the next, improving efficiency and minimizing errors.
Transformative Results
This collaborative effort delivered measurable improvements:
- Reduced RCM implementation time from 16 weeks to 5 weeks per unit.
- Increased maintenance compliance from 75% to nearly 100%.
- Significant reduction in operational risk and vulnerabilities.
- Optimized maintenance processes, saving over 30% in resources.
By aligning reliability practices across its entire fleet, the energy company has not only achieved immediate operational benefits but also established a long-term framework for sustainability and efficiency.
Read the Full Story
Click here to discover the full details of this transformative journey and learn how the combination of MaxGrip’s expertise and Cenosco’s IMS Suite helped achieve fleet-wide excellence.
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