Streamlining offshore maintenance process increases utilization and reduces backlog

Identifying improvement potential
At an international exploration and production company operating in the North Sea, the T.A. Cook team was brought in to examine maintenance and inspection processes and identify opportunities for improvement. 

Following an initial 10-week analysis, the T.A. Cook and client team identified a number of key areas for enhancement. Via a combination of observation, data analysis and interviews with key maintenance personnel, the team concluded:

  • No common process or approach existed within maintenance and inspection;
  • SAP was not used effectively, with low work order notification quality;
  • 50 % of work orders were prepared offshore, creating confusion, delays and poor utilization.

Regaining control of maintenance

Based on the analysis, three key improvements were implemented during an 18 month project. First, in order to separate work preparation from main

trades, one team was given responsibility for all work order preparation, including maintenance, production support and inspection. This supported the philosophy that all maintenance work would be prepared onshore and executed offshore and enabled engineers to focus on large and non-routine work.

Second, to ensure notification quality and install proper gatekeeping measures, key steps for the identification and notification of work orders in SAP were defined. These included exact requirements for the level of detail as well as how prioritization should be carried out.

Finally, to improve performance, a management system was designed and installed. This included the definition of KPIs and served to improve interfaces between departments and streamline reporting.

Results
The number of priority 0 & 1 work orders prepared offshore dropped from 50% to just 2% due to restructuring work preparation.

Proper prioritization and planning reduced the backlog of non-compliant work orders from 2000 to 280.

Furthermore, the utilization of maintenance technicians increased by 50%.