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Maintenance & Inspection Management Services

Hofincons Group provides maintenance & inspection management study services to help clients make good maintenance better.  World best practice knowledge and and expertise is used to best fit the maintenance needs for the client and to adopt right strategies. Hofincons has the ability to translate the maintenance & inspection management services into the Computerised Maintenance Management (CMMS) System. Hofincons is a one-stop partner for all Asset Maintenance & Integrity Management needs. Hofincons offers variety of suites such as:

 

Maintenance / Job Plan Build

Hofincons provides Planned Maintenance Routine (PMR) / Operations Routine (OR) builds, maintenance plans builds, job plan build, task list build. It is built by translating Risk & Reliability studies and/or from generic strategies. Hofincons brings in the world of experience in developing builds for Green field, brown field and for any new CMMS implementation.

 

Work Order Description / Maintenance Craft Procedure development and review
Hofincons provides services to develop the Work Order Descriptions / Maintenance Craft Procedures / Work Instructions by specific or generic strategies and to update them to any Computerised Maintenance Management System (CMMS)

 

Development of SCE, Performance Standards (PS) and Assurance Measures
Safety Critical Equipment (SCE) is part of the installation which prevent, control or mitigate Major Accident Hazards and the failure of which could cause or contribute substantially to a major accident. Hofincons has been working on SCE's from the early days and have in-dept knowledge of Identification of SCE's, Development of Performance Standards and CMMS implementation of SCE's & PS (Performance Standards) with its Assurance Measures & Tasks.

 

Criticality Analysis - Functional Criticality Analysis (FCA) and Equipment Criticality Analysis (ECA)
The Functional Criticality analysis (FCA) is top down identifying the various functions and sub-functions of the facilities. The level of a function is recognised by decomposing to a lower level.

The aim of the Equipment Criticality Assessment (ECA) is develop equipment risk profile or identify the equipment that is most likely to cause the most loss to profitability, safety and the environment. It uses the risk formula to identify the business financial impact if an equipment was to fail.  The criticality ranking is used along with safety, environmental and production performance standards to focus the maintenance strategy development.

 

Function Mode Effect Analysis (FMEA) and Reliability Centred Maintenance (RCM)
Analysis is carried out for identifying failure modes for the function and mitigating it accordingly to reduce the risk level of consequence. A failure modes effects analysis (FMEA) process is used on critical and non-standard equipment. The focus is on the modes and consequence of failure, plant availability/reliability targets and the mandatory performance standards set out in legislation. The process includes a clear audit trail for the decisions made and the drivers behind them.

Reliability Centred Maintenance RCM is a logical analysis applied to determine the maintenance requirements of a physical asset in its operating context. The prescribed decision tree is used to determine the maintenance requirements. RCM analysis elaborates to understand:

 

  • The correct functions of an asset in its operating context under its desired Performance Standards
  • Possible type of its functional failures
  • Types of failure modes that cause each function failure of an asset
  • Failure effects of a critical failure mode
  • Failure consequences of each critical failure mode
  • And, finally what must be done, a suitable mitigation task, to prevent or reduce the failure consequences by the RCM decision approach

 

Maintenance strategies are identified as:

  • Preventive Maintenance - time based
  • Preventive Maintenance - condition based (continuous monitoring or inspection/function test)
  • Corrective Maintenance (planned)

By analysing the inherent reliability of an equipment, critical assets are identified. An effective maintenance program is developed to the most critical equipment. Hofincons will list the proposed maintenance tasks and strategies for implementation into CMMS systems.

Hofincons has worked with methodologies like SAE JA 1011, SAE JA 1012, RCM, RCM2, S-RCM, etc and is conversant with popular software tools.


Risk Based Inspection (RBI)
Risk Based Inspection (RBI) is part of Risk & Reliability Management (RRM) and inline with Asset Integrity & Reliability Management System (AIRMS). The study is carried out based on API 581 The dedicated RBI study will guide where, when and what type of inspection & monitoring is required for particular asset. The objective is to ensure focus of inspection to areas with high risk, while inspection in areas with low risk will be reduced from the normal inspection program.

 

Maintenance Strategy Development
A Maintenance Strategy brings current maintenance practices & operations together with best practice to provide a road map to follow and achieve:

  • Improved operations and productivity
  • Control engineering spending
  • Consistently provide parts for PM with the lowest spares holding value,
  • Engineering compliance to company and statutory standards & requirements
  • Ensure engineering is focused on business objectives

 

Maintenance Optimisation program (PMO)
The need for PMO is to improve the maintenance process and increase effectiveness & efficiency of PM tasks in order to increase Reliability & Availability of the equipment and Plant.

Hofincons supports clients in optimising existing maintenance program based on equipment maintenance history and best practices. Maintenance optimisation eliminates unnecessary tasks ineffective & invasive. The optimisation identifies and includes tasks that are required. Maintenance Optimisation will help to develop an appropriate maintenance strategy to achieve inherent availability of the system / equipment by an integrated approach to achieve reliability.

 

Root Cause Analysis (RCA) and Equipment Improvement Analysis (EIA)
Root cause analysis (RCA) is a class of problem solving methods aimed at identifying the root causes of problems or events.  By directing corrective measures at root causes, it is more probable that problem recurrence will be prevented. There may be several effective measures (methods) that address the root causes of a problem. Thus, it is often considered to be an iterative process, and is frequently viewed as a tool of continuous improvement.

 

Integrated Activity Planning (IAP) services
Hofincons can support companies in planning the maintenance activities in line with needs of equipment shutdown, system shutdown and plant shutdown, thus reducing the downtime and increasing production. The Integrated Activity plans can be setup in client ERP / CMMS systems for immediate implementation of the IAP.

 

Risk Spare Analysis (RSA)
Risk Spare Analysis is to list the spares with critical ranking for the Extreme & High Critical equipments.

  • Classification of spares based on Equipment criticality (Extreme & High critical equipments)
  • Ranking the spares as Vital & Essential Protective
  • Classify stock / non-stock item on the basis of criticality ranking

 

Maintenance Evaluation Study
As competitive pressures grow, managements are looking for ways to reduce the costs and improve production. Quite often decisions involve changes in organization structure, business strategy, spares, training and so on, but leave out the most important cost drivers. Hofincons can support to understand the real cost drivers to improve the production by reducing the plant downtime.

With over 30 years of experience in providing services related to industrial asset management, Hofincons can conduct systematic maintenance evaluation study of your plant and assess your maintenance performance against your objectives. When effectively implemented, the study will be a powerful change tool to establish optimum performance of your plant. The results will throw the options for various strategies, which can be implemented effectively. Furthermore, by effective maintenance can directly enhance equipment performance and reduce maintenance costs.

Through years of industrial asset management experience and best practices, Hofincons has evolved a comprehensive Maintenance Evaluation guide that determines, where you are in terms of today’s best maintenance practices. It includes an evaluation of major functional areas within maintenance operations and covers over 200 evaluation items.

The Maintenance Evaluation Study serves as a means to evaluate each functional area as well as to develop an overall assessment of the maintenance operation. The Scoreboard for Maintenance Excellence provides a convenient working document for developing a strategic plan for continuous maintenance improvement. It can also be tailored by adding specific goals for each type of maintenance operation.

  • Provides “Snap shot” of current maintenance management system addressing both quantitative and qualitative aspects
  • Provides conformity of maintenance processes and strengths in existing maintenance operation
  • Identify key opportunities for improvement
  • Provides a framework to identify the training needs and to address knowledge & skill gaps to achieve better maintenance management
  • Allows organization to assess itself against best practice