Maintenance & Integrity Management

A maintenance strategy built on risk and reliability

Maintenance programs that run on fixed intervals or inherited task lists tend to over-maintain low-risk equipment and under-protect critical assets. The result is higher cost, avoidable downtime and maintenance effort spent in the wrong places.

50+
Maintenance and reliability projects delivered
Criticality-driven
Maintenance priorities set by the consequence of equipment failure
Workshop-led
Analysis run in interactive workshops with your team

What our services cover

Functional criticality analysis

A risk formula ranks each function and piece of equipment by the financial, safety, environmental and production impact of its failure.

Criticality ranking for functions and sub-functions
A risk profile for every piece of equipment
The highest-risk assets identified for maintenance priority
Functional criticality analysis: asset criticality matrix of probability against severity with the highest-risk cells highlighted
Functional criticality analysisAn asset criticality matrix of probability against severity fills from low-risk green to high-risk red, and the highest-risk cells are highlighted as maintenance priorities.ASSET CRITICALITYSEVERITYPROBABILITYMaintenance priority
Reliability-centered maintenance: a pump analyzed from function to failure mode and consequence, ending in a condition monitoring task
Reliability-centered maintenanceFor a pump, the analysis moves from function to functional failure, failure mode and consequence, then selects the maintenance task that best manages the failure.RCM ANALYSIS, ONE PUMPFUNCTIONTransfer feed at design flowFUNCTIONAL FAILUREUnable to transfer feedFAILURE MODEBearing wearCONSEQUENCESafetyEnvironmentProductionProductionMAINTENANCE TASKCondition monitoring: vibrationAgreed in workshop with operations and maintenance

Reliability-centered maintenance

Interactive workshops with your team determine the maintenance tasks that best prevent failure or limit its impact on health, safety, environment and production.

RCM analysis led by experienced reliability and maintenance engineers
Maintenance tasks selected to protect technical integrity

Failure modes and effects analysis

A detailed examination of systems and processes identifies the most probable failure modes and their effect on overall plant performance.

Probable failure modes identified by system
Effects assessed against overall plant performance
Failure modes and effects analysis: failure modes traced along a cause-and-effect diagram to their effect on plant performance
Failure modes and effects analysisProbable failure modes are identified along each branch of a cause-and-effect diagram and traced to their effect on plant performance.Effect on plantperformanceProbable failure modes by system
Preventive maintenance optimization: six existing pump tasks reviewed, with four retained
Preventive maintenance optimizationExisting preventive maintenance tasks are reviewed one by one and kept, re-intervaled, moved to condition-based, merged or removed, leaving a smaller, focused program.EXISTING PM TASKS, ONE PUMPDECISIONVisual inspectionWeeklyKeepLubricate bearingsMonthlyChange intervalReplace bearings12 monthsCondition-basedCheck alignment6 monthsKeepVisual inspection (2nd route)WeeklyMerge duplicateClean strainer (not fitted)MonthlyRemove6 tasks reviewed, 4 retainedFocused on how the pump actually fails

Preventive maintenance optimization

Each piece of equipment gets the most suitable maintenance technique and interval, balancing regulatory, safety and reliability goals against the resources available.

Maintenance technique selected for each equipment item
Task frequencies set to meet regulatory, safety and availability targets

What the right maintenance strategy delivers

Longer equipment life

Lower maintenance costs

Less unplanned downtime

Maintenance effort focused on critical assets

Focus maintenance where it matters most

Share how your maintenance program runs today, and the Hofintech team will recommend where to start.

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