9 Areas to focus on to improve reliability of a continuous process plant
1. Develop a robust equipment maintenance strategy
a. Focus on Preventive Maintenance
b. Criticality Assessment
c. Application of Condition Based Monitoring
2. Maintenance Capabilities
a. Capability building program
b. Team based work culture
3. Develop equipment investment strategy
a. Plan for equipment replacement
4. Maintenance planning and scheduling
a. Preventive Maintenance Planning
b. Preventive Maintenance Plan Adherence & Execution
c. Shutdown Planning
5. Work Execution
a. Availability of tools & tackles
b. Use of breakdown analysis
c. Workplace Management (5S)
6. Reliability Centered Production
a. Use of SOPs by production crew
b. Autonomous Maintenance
7. Performance Management
a. Rewards & Incentives
b. Use of Visual Management
c. KPI tracking and reviews
8. Maintenance Organisation
a. Construct of Maintenance Organisation
b. CBM team structure
9. Maintenance Infrastructure
a. Use of ERP for Maintenance Activities
b. Spare part availability and quality
c. Knowledge Management
d. Contractor performance management
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