In the Oil & Gas industry, maintenance productivity is closely linked to operational efficiency. Despite the uncertainties surrounding supply and demand, costs, and regulations that make achieving profitability challenging, maintenance is one area that companies can manage effectively. By improving maintenance productivity, oil and gas companies can enhance cash flow and better navigate industry challenges. Increased maintenance productivity not only boosts operational efficiency but also minimizes downtime and manages costs more effectively. Therefore, monitoring and enhancing maintenance productivity should always be a top priority.

‍

Achieving maintenance productivity and effectiveness is a tedious process. Developing maintenance Standard Operating Procedures (SOPs) and fostering a cultural shift requires data, guidelines, consensus among various stakeholders, and several other essential components. The diagram below summarizes the key building blocks of an effective maintenance strategy:

‍

Here is a step-by-step approach for achieving and monitoring the maintenance productivity.

1. Defining Productivity Metrics and KPIs

The first step in building a robust maintenance productivity monitoring plan is to zero down on the key performance indicators (KPIs) that will be used to measure improvement. The KPIs will provide clarity and help shape the execution strategy. While the specific KPIs may vary slightly depending on the unique situation and priorities of each plant facility, here are some metrics that Oil & Gas companies can use to assess their maintenance productivity:

• Planned vs. Actual Maintenance: Comparing scheduled maintenance tasks to completed tasks.
• Mean Time to Repair (MTTR): The average time taken to repair equipment and restore functionality.
• Mean Time Between Failures (MTBF): The average time equipment operates without failure.
• Preventive vs. Reactive Maintenance Ratio: Percentage of preventive tasks compared to reactive repairs.
• Equipment Availability: The percentage of time equipment is operational and available for use.
• Work Order Completion Rate: The percentage of maintenance work orders completed within a given timeframe.
• Maintenance Backlog: The total outstanding maintenance work measured in hours or days.
• Cost per Work Order: The average cost associated with completing a maintenance task.
• Maintenance Overtime Percentage: The ratio of overtime hours to total maintenance hours.

‍

2. Data Collection and Integration

Once the KPIs are finalized and agreed upon by all the stakeholders, the next crucial step is building the data collection and integration mechanism. The quality and reliability of the data will define the success or failure of all further efforts. These are the most common areas from where the data for monitoring and finding out opportunities to improve will be gathered:

• Sensors and IoT Devices: Gathering data on equipment performance, temperature, vibration, pressure, etc., to identify issues early.
• Computerized Maintenance Management Systems (CMMS): Centralizing maintenance data, tracking work orders, and scheduling tasks.
• Enterprise Asset Management (EAM) Systems: Integrating maintenance data with broader enterprise resource planning (ERP) systems.
• Manual Logs and Reports: Collecting data from technicians for tasks not covered by automated systems.

‍

3. Leveraging Advanced Analytics

The number of assets maintained in an average-sized plant will be large. Also, the data will be gathered from multiple locations and formats and will need to be standardized, cleansed, and transformed. Once the data is ready for use, the organization will need advanced analytics tools to make the most of it in the least amount of time. 

• Predictive Analytics: Using historical data and machine learning to predict equipment failures and optimize maintenance schedules.
• Performance Dashboards: Real-time visualization of maintenance KPIs and trends.
• Root Cause Analysis (RCA): Identifying recurring problems and addressing their root causes to improve productivity.

‍

4. Maintenance Planning and Scheduling

After capturing and analyzing the data, the next crucial step is to transform that data into actionable insights and implement improvements within the plant facility. This will enhance the efficiency of plant operations. The following tasks will help ensure this improvement:

• Workforce Allocation: Ensuring optimal staffing levels and skillsets for each task.
• Prioritization: Ranking tasks based on criticality to production or safety.
• Downtime Management: Scheduling maintenance during planned shutdowns to minimize production impact.

‍

5. Continuous Monitoring of Work Execution

Monitoring of the actual maintenance-related activities being conducted on the floor is also necessary. The time taken to identify spare parts, retrieve them from the stores, execute precise maintenance procedures, and similar activities impacts the efficiency and effectiveness of maintenance. Here are some standard mechanisms to ensure maintenance efficiency and quality: 

• Mobile Solutions: Using tablets or smartphones for real-time updates from technicians in the field.
• Time Tracking: Monitoring the time taken for individual tasks using digital tools.
• Compliance Checks: Ensuring that tasks meet safety and quality standards.

‍

6. Benchmarking and Goal Setting

Any project can veer off course if it lacks concrete goals. Fortunately, the Oil & Gas industry follows established standards, providing numerous benchmarks to help set these goals. The following activities can aid in defining achievable objectives:

• Historical Comparisons: Comparing current performance with historical data to identify improvements or regressions.
• Industry Benchmarks: Measuring against industry standards to gauge competitiveness.
• Target Setting: Establishing productivity targets and tracking progress.

‍

7. Regular Reporting and Reviews

Maintenance is a routine activity, and hence, it should be reviewed regularly. It is very important to establish reporting formats and frequency before the project commences. The reports should directly link to relevant and important KPIs.

• Daily/Weekly Reports: Tracking short-term performance metrics.
• Monthly/Quarterly Reviews: Analyzing trends, identifying bottlenecks, and adjusting strategies.
• Management Dashboards: Providing high-level insights for decision-makers.

‍

8. Optimizing Maintenance Strategies

When it comes to maintenance, a 'one size fits all' approach is not effective. Implementing multiple strategies can enhance maintenance outcomes and reduce costs. Here are the most common maintenance strategies used by Oil & Gas companies:

• Condition-Based Maintenance (CBM): Performing maintenance based on real-time equipment conditions rather than schedules.
• Reliability-Centered Maintenance (RCM): Focusing on strategies that maximize the reliability of critical assets.
• Total Productive Maintenance (TPM): Involving operators in basic maintenance tasks to improve productivity and ownership.

‍

9. Training and Workforce Productivity

Although everything can be digitized, physical maintenance is still a manual task. Hence, productivity of maintenance personnel plays a key role. Here are some quick wins that can boost the productivity of the maintenance team:

• Skill Assessments: Regularly evaluating the technical skills of maintenance staff.
• Ongoing Training: Providing technical and safety training to enhance productivity.
• Team Collaboration Tools: Using platforms to improve communication and coordination among teams.

‍

10. Cost Monitoring

Cost of maintenance is always a critical parameter to monitor. Oil & Gas organizations should periodically carry out the following to monitor costs: 

• Budget Adherence: Comparing actual maintenance costs with budgeted amounts.
• Cost Drivers Analysis: Identifying factors driving up maintenance costs and addressing inefficiencies.

‍

11. Technologies Enhancing Maintenance Monitoring

Technology can be useful for improving maintenance efficiency and reducing costs. It can significantly enhance the monitoring of inaccessible assets that are otherwise challenging to maintain. Here are some of the most common maintenance tracking technologies gaining traction in the Oil & Gas industry:

• Digital Twins: Simulating equipment performance for predictive maintenance.
• AI and Machine Learning: Enhancing failure prediction and task prioritization.
• Drones and Robotics: Inspecting hard-to-reach areas to minimize risks and improve efficiency.
• Augmented Reality (AR): Assisting technicians with visual guidance and remote support.

‍

Summary: 

Monitoring and enhancing maintenance productivity is not a one-time task; it must be ingrained in the organization's culture. Depending on each organization's unique needs and challenges, a comprehensive strategy can be developed using the suggestions discussed in this article.