The right maintenance approach for each asset strikes a balance between cost, risk and performance. Over maintenance consumes valuable resources and productive operating time, while insufficient maintenance increases the likelihood of costly, unplanned failures. Getting this balance right — asset by asset — is one of the most effective ways to improve operational and business performance.
We help clients design and optimise their maintenance programs by identifying the right tactic for each asset, prioritising based on criticality, and integrating the plan into a funded and governed budget that can be sustained over the long term. While we specialise in mining, we also support energy, pulp and paper, and other asset-intensive industries.
Selecting the right tactic
Using Reliability-Centred Maintenance (RCM), Condition-Based Maintenance (CBM), Risk-Based Inspection (RBI) and Planned Maintenance Optimisation (PMO), we develop the right mix of maintenance tactics for each asset's criticality and failure mode, from new assets at the design stage, through maintenance readiness and value engineering, to established operations where an existing program needs refining.
Prioritising by criticality
The loss or shutdown of a critical asset — planned or unplanned — can carry major financial and operational consequences. Using a decision matrix and proven methodology, we categorise assets by criticality, identifying those vital to operations and that carry the greatest safety, health or environmental risk, so that maintenance investment goes where it matters most.
Funding the plan
We integrate maintenance planning into budgeting and forecasting processes, including OPEX and zero-based budgeting, using CMMS data and key performance indicators to ensure plans are properly funded, controlled, and adjusted as conditions evolve. Our experts have advised maintenance teams worldwide on Total Cost of Ownership (TCO).
Optimising the wider process
Maintenance strategy sits within the broader performance of the operation as a system. Where value is being lost due to hidden constraints or bottlenecks, we help identify opportunities for improvement, quantify what they are worth, and design debottlenecking and process improvements that increase overall throughput — making sure a gain in one area doesn't simply move the constraint somewhere else.
Our services include:
- Maintenance-tactic selection and plan design (RCM, CBM, RBI, PMO)
- Design and optimisation of maintenance and inspection plans
- Maintenance readiness and value engineering for new assets at the design stage
- Asset-criticality analysis and prioritisation
- Shutdown, turnaround and overhaul strategy
- Asset strategy development and optimisation
- Budgeting and forecasting integration (OPEX, zero-based budgeting and TCO)
- Constraint identification, debottlenecking and process improvement
- Ongoing advisory support to update plans as conditions change
The result is a practical, sustainable maintenance program that aligns effort with risk and criticality, is supported by appropriate funding and governance, and remains responsive to changing asset and operational needs.