Typical maintenance readiness activities performed during a project life cycle
Most asset-related projects are managed through a stage-gate process, with typical stages listed in the infographic below.
The maintenance readiness framework functions in a similar way to a generic project plan where we assist in meeting the client’s requirements. We provide support as they progress through each review stage of the project.
Pragma has customised a generic project model through which it achieves maintenance readiness for specific client needs as is described in the stages and activities below.
Pragma Maintenance Readiness Project Model
Stage 1 | Opportunity / concept
At this stage, the client will still be evaluating a variety of opportunities to produce a robust business case. Therefore, our involvement is limited to providing the client with estimates of what the typical maintenance readiness activities are, and the effort entailed to reach them should the project proceed to the pre-feasibility stage. This will enable the client to enter the next stage with a clear plan and budget provision for completing the required maintenance readiness work during pre-feasibility.
Stage 2 | Pre-feasibility
We can provide the most value for our clients if we are on board from the pre-feasibility phase. This is where the reliability specifications are documented, based on the asset strategies and the detailed design determined from the initial notational designs. The intent of the pre-feasibility phase is to define the investment details for the selected alternative and confirm the business case. The end result is that the client is provided with:
- Maintenance readiness plan and budget for Feasibility
- Maintenance readiness team proposal for Feasibility
- Draft EAMS plan
- Tested reliability specification for the project
- Preliminary details for critical assets
- Maintenance support requirements
Stage 3 | Feasibility
Once the business case has been defined and agreed upon, this is refined in the feasibility phase. RBD diagrams are refined, and further RAMS and RAMBO analysis is also carried out if required. The end result is that the client is provided with:
- Updated maintenance readiness plan and budget for Execution
- Detailed Maintenance team (considering outsourcing decisions)
- Document Management systems for maintenance readiness deliverables and a detailed EAMS plan
- Reliability and maintainability analysis to influence the final design
- Detailed specifications in support of the procurement packages for critical equipment
- Detailed asset tactics development plan to be implemented during the Execution stage
- Plans to deliver maintenance facilities, tools and spare parts
- Any life cycle costing calculations to clarify asset selection
- Design the performance measures and tools for critical equipment
Stage 4 | Execution
During Build and Deliver, most of the plans developed during feasibility need to be executed. This includes:
- Develop the detailed functional location structure and asset register
- Develop all the maintenance tactics and populate the chosen EAMS
- Deliver the training plans for the new team, or finalise agreements with outsourced service providers
- Identify, code and procure all of the maintenance spare parts, and establish the initial stock parameters
By the time the project reaches Commissioning, the maintenance management and reliability management functions are in place for operating the new assets. They will have the responsibility to build on this foundation and also drive the long-term asset management plan.
The site and project teams should establish an agreement as part of the commissioning plan, that describes in detail the project handover and acceptance criteria. This will ensure that both teams are aligned and will work towards the same target. The involvement of the operational team from an early stage in the project will ensure a smooth handover of the investment.
Stage 5 | Operation
In the end, it all comes down to operating the investment to achieve the business case. Here we can assist with:
- Conduct RCAs on problem areas
- Facilitate the Post Mortem of the project and document the lessons learned
- Ensure final documentation, asset registers, maintenance plans and spare parts are updated to ‘as-built’ status