Implementing a New Maintenance and Reliability Strategy across multiple Global Chemical Plants to improve Asset Availability and Maintenance Productivity

Client Context

A chemical manufacturing company was operating in a highly reactive mode, experiencing significant production losses due to low asset availability.

Management recognized the need to develop a standardized Reliability Program across all sites to:

• Stabilize operations by identifying quick-win improvements.
• Enhance maintenance efficiency, reducing rework and optimizing contractor utilization.

Key Challenges

• Frequent production disruptions due to poor asset availability.
• Lack of a structured reliability strategy across multiple sites.
• Reactive maintenance culture, with high emergency work orders.
• Inefficient maintenance execution, reducing productivity.

Approach & Key Success Factors

EFESO implemented a comprehensive maintenance and reliability strategy using its Best Run Chemical Operations Playbook to improve maintenance productivity and equipment reliability.

1. Reliability Program & Cultural Transformation

• Established joint operations & maintenance teams to drive equipment reliability.
• Introduced leader walks for early failure detection.
• Developed Equipment Criticality Programs and Reliability-Centered Maintenance (RCM) strategies.
• Implemented Bad Actor Root Cause Problem-Solving Program to eliminate chronic failures.
• Formed Equipment Improvement Teams to restore equipment to OEM standards.

2. Maintenance Process Optimization

• Defined Equipment Care Procedures to improve asset longevity.
• Introduced KPI-driven performance management to ensure accountability.
• Implemented new planning and scheduling processes for maintenance efficiency.
• Launched a Barrier Elimination Program to remove productivity roadblocks.

3. Organizational Alignment & Standardization

• Defined new roles and responsibilities to support reliability initiatives.
• Developed training programs for facilitators and support teams.
• Created a Playbook Approach to document methodologies and sustain improvements.

Results

$9.7 million

In annual pre-tax earnings improvements (12%).

20% to 75% increase

In Preventative Maintenance Work Orders.

27 Bad Actors resolved

Preventing recurring equipment failures.

9 Equipment Improvement Teams

Deployed to restore assets to OEM standards.

RCM strategy

Implemented across 8 plants.

60% to 15%.

Emergency Work Orders (P1) reduced.