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Optimizing Maintenance: CMMS for Oil & Gas Data

Optimizing Maintenance: CMMS for Oil & Gas Data

oil & gas industry maintenance

How CMMS Software Facilitates Real-time Data Analysis and Reporting in Oil & Gas Maintenance

Role of the Oil & Gas Industry

The oil & gas industry delivers people the bulk of their daily energy needs for electricity generation, heating, and cooling, cooking, transportation, etc. It is inseparably associated with complexities and unique challenges. The laborers work in far-flung and hostile environments. It is becoming increasingly expensive and difficult to extract energy. Business owners seek opportunities to maximize investments and minimize operating expenses.

Why CMMS for Oil & Gas business?

Business owners appreciate access to relevant operational data that is precise, reliable, and timely. Leading oil and gas agencies use computerized maintenance management software(CMMS) to organize the maintenance of their refineries, eradicate sudden equipment repairs that hits productivity and costs heavily to reinstate the equipment to working condition. A capable CMMS improves emergency response with simple but powerful workflows. It lends a helping hand in meeting safety and statutory regulations and helps dilute the higher degree of risks inherent in the installation and extraction process.

Go beyond preventive maintenance for deep savings

An Oil & Gas CMMS automates preventive, predictive, and corrective maintenance. Oil & Gas industry was one of the earliest adopters of predictive maintenance. A stitch in time saves nine. As the oil & gas business involves robust machinery, an IoT-based Condition monitoring technique anticipates when the equipment nears failure with abnormal operating parameters and automatically alerts the stakeholders. Go a step deeper in cost savings by avoiding overdoing preventive maintenance.

Environmental Care and Operator’s Safety

In certain instances, critical equipment failures may cause spills and leaks that harm operators and environmental health. It calls for frequent inspections daily. It is common to forget or skip certain tasks. Hence automate inspection tasks to receive mobile alerts on each task due for the day. Maintenance supervisors can add schedules to educate and remind workers about safety practices to address safety concerns.

CMMS for Large-Scale Oil & Gas operations

A project undertaken by Oil & Gas business involves many equipment, installations, and technicians. Important events such as turnarounds may last up to a few months. If companies ignore maintenance for several months, it will magnify the losses due to turnarounds and shutdowns with the flagging of additional issues and prolonging of shifts. Oil and gas operations generate numerous readings.

It will be challenging to extract useful operational metrics from the vast pool of data without the right tools. A CMMS comes into the scene here with predictive analytics abilities.

Oil & Gas operations at optimum efficiency 

With superior automation and top-notch visibility management, InnoMaint’s Oil and Gas Enterprise Asset Management software helps everyone in the field work at optimum efficiency. Techs easily navigate the application and carry out their work with clear and easily interpreted instructions with images, voice, or video illustrations. Regular maintenance using a digital solution reduces maintenance expenses while enhancing productivity levels. Employees are more productive, exhibiting better communication and contributing to improved processes.

Real-Time Technician Tracking

Admin can track a technician’s movement in transit with Geo-Location Tracking for much-needed transparency on travel and reporting. The free mobile app automatically reports various aspects of technician performance eliminating manual reporting. Maintenance supervisors can rely on the high degree of accuracy of the real-time data reported by the cloud-based maintenance application.

With automation, work order management is a gentle breeze. Supervisors can manage oil & gas assets effortlessly at all stages of their lifecycle by just assigning work orders with visibility of real-time workload, attaching priority labels, sending automatic mobile alerts, setting reminders, deadlines, etc. They can catch up with correspondence while on the move and view information on any closed, outstanding, or scheduled work orders from a 52-week PPM calendar.

 Oil & Gas inventory management

An EAM can provide crystal clear visibility into inventory stock, inward and outward movements across the inventory. It hints at the spare demand for the current year based on previous usages, help you procure spares by comparing various quotes and choosing the best, etc. Save inventory costs significantly by preventing purchases, losses due to theft, etc. No more manual filing the invoices, purchase orders, and quotes. We live in the digital age!

Data analytics rich Dashboard

Maximize performance of all oil & gas assets and measuring instruments with data analytics rich EAM/CMMS application. With customizable Dashboard, you can select the Key Performance Indicator(KPI) metrics that matter the most. Know asset health, maintenance costs, Preventive Maintenance compliance, equipment downtime trends, etc. requiring immediate attention with a quick view of the Dashboard from anywhere.

Accelerate Decision making with customized reports

Speed up your decisions to improve productivity and meet the market demands with consolidated reports on every aspect of maintenance, such as performance report, transactional report, asset movement report, spare report, IoT reports, and much more. Simplify equipment maintenance for the benefit of all stakeholders of the maintenance management business. A CMMS helps you reduce downtime by 50%, improve repair time by 30% and maximize asset life expectancy time. Simplify day-to-day operations by emulating the successful path of leading Oil & Gas companies!

To Monitor Equipment Health and Performance in Real-time

Try Innomaint Oil & Gas
Industry Maintenance Software

6 Tips to Reduce Equipment maintenance costs

6 Tips to Reduce Equipment maintenance costs

workorder management software

6 Tips to Reduce Equipment maintenance costs

Equipment maintenance costs form a significant portion of overall business expenditure and can elevate your profits when managed sensibly using CMMS software. An urge to limit maintenance spending is quite common. The temporary benefit shall be counterproductive and a license for unforeseen consequences, in terms of service costs and risks, in the long run.

CMMS software helps technicians best discharge their duties by offering instant access to checklists, documents, manuals, resources, knowledge base, etc. It provides for future planning and easy work order reference at a later stage. Read on to learn the importance of digital work order management.

Maintenance costs invariably include:

  • Staffing costs for internal maintenance staff or contract costs owing to delegation of work to a third party.
  • The cost to bring a failed equipment back to work, including reduced productivity in the transit period.
  • Consumables cost such as the cost of lubricants, tools, etc.
  • Cost of spares needed for completion of service such as bearingsfittingsfasteners, etc.

Is it possible to reduce maintenance costs overnight?

Absolutely no, but it is possible to set a solid foundation by exercising control over your work orders and maintenance budget using a systematic digital approach. You can realize the tasks you were overdoing and ignoring for a long time.

How?

A maintenance automation solution lets you identify

  1. business-critical equipment
  2. Equipment with the highest preventive maintenance costs;
  3. equipment that depends on another for its operation
  4. equipment with the highest number of work hours
  5. The default user of the equipment
  6. maintenance history of the equipment
  7. skill set and performance of each technician

With the above knowledge that is easily retrievable from a mobile or laptop, it becomes easy and crystal clear to devise the appropriate maintenance strategy that is cost-effective as well. A stitch in time saves nine!

Work order management software lets managers glance, assign, schedule, and prioritize all maintenance tasks. It helps them know the outstanding backlog count, areas of delay, the ratio of planned and reactive maintenance, frequently failing assets, spot specific business locations that lag in maintenance performance, etc., with a glance at the Dashboard using their mobile app.

Let’s delve deeper into the reduction in equipment maintenance costs.

An ideal maintenance expense reduction plan should aim for long-term cost reduction, make the least or insignificant impact on production, and provide a safe operating environment.

How to Reduce Equipment Maintenance Costs?

1. Eliminate repetitive tasks

You resort to preventive maintenance as reactive or breakdown maintenance costs 3 to 9 times more than routine maintenance. Statistics reveal 30% of preventive maintenance tasks are overdone meaninglessly. As the breakdown patterns of certain equipment are irregular, refine preventive maintenance schedules unique for each asset model and id.

Fix maintenance frequency based on usage, calendar, or operational parameter values. Drop tasks that are not associated with any failure modes. Invest some time in analyzing the root causes of a failure that will help minimize breakdowns in the long run.

2. Use High-Quality Spare Parts

Sourcing and fitting sub-standard parts reduces maintenance costs, but a business will incur more expenses eventually as the components tend to fail soon. Remember that low-quality parts do not undergo adequate quality control accounting for the low price. How nice would it be to procure genuine spares and assets by comparing quotes from various suppliers in a single window from the maintenance management software? You could do so by minimizing purchase delays at the best prices. Some software even go a step further in automating actions such as adding items to the purchase order list once the inventory items go below minimum re-order levels. With a workflow for checking the quality and quantity of purchased parts, you can order in bulk to negotiate better prices and facilitate purchase returns.

When such a facility is available, why do it manually?
Please ensure you lubricate the machine well, as poor lubrication is a common cause of machine failure. Lubricant is cheap, unlike gears, bearings, bushings, etc. You can automate lubrication tasks so that maintenance staff never forget it.

3. Reducing the labor and travel costs

Many plants face a shortage of craftspeople. Skilled workmen are rare these days. So it is necessary to make the best use of each technician. For this, you should have an insight into their real-time workload at any time. Get this insight from your mobile app at the time of assignment of tickets. With punch-in, punch-out, check-in, and check-out abilities, you can measure the actual work time for each day and task-wise time split-up. With digital work estimates and measurement of time, it becomes easy to negotiate and control final costs. Not just that! Field managers or customers can track the entire journey of a technician live via Geo Location tracking. Thus they can help them choose the shortest and best route to minimize fuel costs and production losses.

4. Optimize the asset life cycle 

If an asset fails repeatedly despite the best service, consider if it’s worth repairing. Knowing the current depreciation value of the asset using various techniques available in the market can help decide the right time for recycling or disposing it. The procurement management module integrated with the CMMS accelerates the asset replacement process by speeding up purchase request approvals, helping in obtaining quick invoices from various suppliers, and procuring the best products at the cheapest rates.

5. Train your entire team

Technologies evolve and advance with time. Not everyone on the floor is technology proficient. It is important to train every maintenance stakeholder – not just the technicians. The reason is the earlier an equipment failure or malfunction is spotted, the earlier it is fixed, reducing labor effort and costs. Employees or customers should acquaint themselves with the application usage to raise defects effortlessly using QR code mobile scan with a multimedia attachment of an image or short video to bring the issue to the notice of the maintenance team. Thus you can avoid costly and complicated repairs.

6. Standardize & simplify maintenance procedures 

Machinery may be robust with complicated operating procedures. But maintenance instructions for the machinery shouldn’t be so. Senior Techs can document maintenance procedures by breaking them down into checklist levels. It helps techs with lesser experience and skills to perform complete maintenance without skipping steps.

The CMMS application shall let a technician complete a maintenance task only after marking all checklists as complete. Besides, you can retain the knowledge of technicians based on incidental data for commonly occurring issues to boost First Time Fix Rates(FTFR). When FTFR improves with sensible solutions, Mean Time Between Failure(MTBF) also improves, cutting maintenance costs.

Can you afford to lose the above said advantages offered by a digital solution for maintenance management?

Act fast to achieve cost-optimized maintenance for business prosperity and sustenance!

Want to achieve cost-optimized maintenance for the prosperity and sustainability of your business?

Try Innomaint CMMS Software!

KPIs Every Facility Manager and Owner Should Track

KPIs Every Facility Manager and Owner Should Track

oil & gas industry maintenance

KPIs Every Facility Manager and Owner Should Track

Dashboard

Importance of Facility Management KPI and metrics

Facility management is an ever-evolving discipline. In the digital age, facility owners and managers should familiarize themselves with extracting useful Key Performance Indicators(KPIs) and metrics from Facility management software. Learn current progress and plan for continuous improvement to provide high-performing facilities free from any annoying interruptions to the core business functions.

FMS KPIs eliminate the need for a physical presence

Check your facilities from the comfort of your workspace or hangout spot via a mobile app. Spot operational inefficiencies along the way to arrive at refined decisions. It’s just as simple as that. Why break your head on facility management issues that steal your attention

OEE Indicators

Facility management software KPI Analysis

Analyze the performance indicators to develop plans for providing adequate training, improving asset management, and streamlining operations for the best

  • Asset performance    
  • Business sustenance
  • Safety of occupants
  • Comfort
Valuable Facility Management KPI & metrics

oil & gas industry maintenance

Facility management software helps manage the facility operations to achieve operational excellence and consistency. Find below several KPIs and metrics for your reference. Kindly note the slight variation between the terms KPI and metrics. For an explanation, please refer to 5 Things You Should Know About Maintenance KPI Metrics

The ratio of reactive work: The KPI reveals the attitude of your Facility maintenance team. It lets you know if they are stuck in reactive maintenance or are forward-thinking with a preventive approach. Reactive maintenance is four to six times costlier than scheduled maintenance. 

PM program compliance: The KPI indicates the degree of adherence of preventive maintenance programs to the result-oriented service level agreements. A successful PM program covers the majority of assets. It aims to complete inspections, monitoring, and approval tasks on time.

Response Time: It is the average time technicians take to respond to maintenance requests or issues. A shorter response time indicates an agile facility management system.

Energy Consumption: The metric measures the electric power consumption. As well known, electricity expenses make for the highest utility expenses of a business. 

oil & gas industry maintenance

Compliance: The KPI measures the extent of adherence to the norms laid down by the regulatory bodies. Meeting compliance standards guarantees safety and is indicative of a well-managed facility. 

Planned Maintenance Percentage: The KPI measures the percentage of maintenance tasks planned ahead of time. A higher score indicates lesser unplanned downtime.

First-Time Fix Rate: This metric indicates the average percentage of maintenance requests resolved on the first visit. Achieve higher scores through the reuse of knowledge, better collaboration among techs, access to digital checklists via mobile, etc. 

Mean Time Between Failure (MTBF): The KPI measures the average time between successive failures for key assets. It reflects the quality of fixes provided by the facility management teams. 

Mean Time to Repair (MTTR): The metric conveys the average time to repair an asset since failure. A lower MTTR indicates the efficiency of repair processes and shrinks downtime.

Cost of Unscheduled Maintenance: The KPI helps key facility stakeholders calculate the cost of sudden breakdowns by revealing the count of failed equipment, total hours worked, and spare consumption. It helps facility owners and managers understand the negative impact of reactive maintenance on the maintenance budget. 

Employee rating: The average rating customers provide to technicians performance and attitude. It helps supervisors better understand the customer experience.

Work Order resolution times: The KPI shows the efficiency of maintenance workflows. If work orders seem to prolong unduly on average, it may be due to a lack of proper planning, coordination among teams, hurdles in the process, etc., which requires investigation.

Planned vs. reactive maintenance: If the reactive maintenance exceeds a certain threshold, you aren’t likely to succeed in your maintenance program. 

Spare Forecast: Forecast spare demand for current year based on the trends during the previous year. Avoid last-minute bulk procurement. 

Recurring Jobs only: The metric provides the count of jobs that have reopened and are outstanding after the initial fix. It could hint at a piece of aging equipment, an incomplete fix, or a missed preventive maintenance task.  

Open jobs count technician-wise: At times, facility managers may be interested to know the current workload of a technician even before assigning work orders to the latter. View this information outright from the application dashboard.

Breakdowns in graphical form: View breakdowns categorizing them based on severity so that breakdown of critical devices captures your attention immediately. 

Active service contract count: The metric provides the total count of active contracts, including internal and external. 

Average Travel Time: The metric conveys the average travel time by technicians to reach the customer site. The time can be calculated with great precision by Geo-Location tracking. 

Mapped-Unmapped Assets: The application maps assets to technicians, locations, and spares for a well-organized approach to maintenance. Bring the unmapped assets under the scope of the application quickly. 

Purchase orders awaiting approval: The metric helps you know the purchase orders that wait for serial or parallel approvers. 

Dashboard to measure facility performance

Discover the true worth of your team with a glance at the figures calculated in real-time by the cloud-based Facility management software. If you struggle to measure performance, you’ll end up managing facility operations ineffectively. 

Key performance indicators (KPIs) provide you with a trailer of your facilities’ readiness to achieve the desired level of success. You can customize the visualization to create the perfect dynamic dashboard to suit your needs and preferences with the data captured by IoT devices. 

It also provides these marked benefits:

  • Justify the budgets 
  • Back formulated strategies
  • Identify areas of concern
  • Contend for sanction of funds 
  • Automic and accurate reporting 
  • Improve day-to-day operations

Free Ebook on EAM: A Guide to comprehensive asset management with modern technology

Free Ebook on EAM: A Guide to comprehensive asset management with modern technology

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Free Ebook on EAM: A Guide to comprehensive asset management with modern technology

Digital transformation differentiates between industry startups and seasoned players in the market. As digitization continues to penetrate several business functions, it is being increasingly adopted for internal maintenance operations too!

InnoMaint has come up with an E-book to lend a helping hand to the business community who wish to carry out maintenance operations internally in a hassle-free and efficient manner with great returns on investment.

Gather all the information necessary to evaluate an Enterprise Asset Management software against the unique maintenance needs of your organization. Find the right and best fit EAM system for your maintenance teams keeping in mind your primary business goals, technological, functional, and scalability-related shortcomings and pain points you face with manual and traditional approaches to maintenance management, etc.

The E-book guides maintenance managers to invest wisely in mastering the art of maintenance management. It sheds light on the modern technology that helps you achieve excellence in maintenance management while improving the average response time, first-time fix rates, and service turnaround time – all with a limited workforce and minimum budget.

Learn how easy it is to gain a holistic real-time view of your stationary and moving assets to optimize their performance, deploy them based on business needs, safeguard them, and optimize maintenance costs. The visibility comes via a mobile app in a completely wireless setup at pocket-friendly rates.

Read about gathering accurate data on operations and reviewing them at the speed of your mind 24×7 from anywhere. End long-term problems of emergency breakdowns by gaining knowledge on the right mix of maintenance strategies that work out wonders bringing all business stakeholders closer in a single digital pipeline. The book lets you realize that you can make huge volumes of work order backlogs an identity of the past!

After reading this Ebook, you will know:

  • Why do companies switch to an EAM to manage their maintenance and repair works.
  • How digital technologies transform and elevate asset management standards.
  • How to opt for EAM software that will alleviate your pain points regarding maintenance management.
  • How to reason out the rationale for asset decisions.
  • The stunning benefits IoT technologieshave in reserve for your facilities after covering essential aspects.

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Familiarize yourself with measuring the performance of business locations, assets, service engineers, etc., to set performance goals and establish good performance digitally without any strain.

Acquire tips for best practices on inventory and spare parts management, reducing the unnecessary stress and burden on the shoulders of your maintenance supervisors, simplifying the process of work request submission, etc.

A well-created work order with clear and complete information on problem statements, raised as soon as a defect is noticed and routed into the system amounts to 50% of completion, isn’t it? Gain a fair idea of new-age technologies and powerful workflows to achieve this.

Visualize the usefulness of features and optional modules. Have further questions? Feel free to approach our experts for guidance on choosing a package that fits your business needs.

Download, read, and share the valuable resource with your business contacts.