Building a maintenance foundation for a first-of-its-kind facility.
Our client is a global technology giant developing advanced solutions for the energy transition. They were building a brand-new production facility based on entirely new technology – equipment and processes that had never been done before.
The plant was designed to be state-of-the-art from day one. High uptime, stable operations, and long-term efficiency were critical. To support this, they wanted 4th generation maintenance that was predictive, proactive, and lifecycle driven. Not traditional reactive approaches, but a maintenance setup at the highest level.
Our client had extensive experience operating industrial facilities, but this project was different. The technology was new. The equipment unique. And there was no historical data to build on. They wanted world-class maintenance.
But they faced common problems:
They needed to bridge the gap between project delivery and future operations – making the plant Ready for Operation (RFO) before handover.
Our job was to ensure the plant was ready for proper maintenance before operation began. We needed to ensure clean data, working systems, and clear processes were in place from day one.
1: Maintenance Management System (MMS) document
We worked with the top management to define their maintenance philosophy and targets, then created the governance document (MMS) describing processes, and workflows that would deliver on those goals.
2: ERP structure and configuration
We configured the ERP (SAP PM) and built a complete asset hierarchy to reflect the real installation.
3: High-quality master data
We mapped and validated equipment data, technical objects, spare parts, and bills of materials, ensuring everything was connected to the right assets.
4: Documentation linked to assets
We reviewed, validated, and structured project documentation so it was accessible, usable, and trusted in daily maintenance work.
5. Maintenance plans from day one
We created and uploaded maintenance plans, so maintenance activities were live when operations took control of the plant.
6. Critical spare parts analysis
We conducted a critical spare parts analysis to ensure the right spare parts were available, reducing risk of downtime caused by missing parts.
7. Training and onboarding
We trained the operational team in both the system and the principles behind 4th generation maintenance, focusing on why data quality and correct reporting matter – and how it benefits them in the long run.
Key outcomes:
Without this foundation, the plant would still have started operations. But the cost of catching up on missing data, unclear structures, and inefficient systems would have been significant.
Instead, our client started from day one with a maintenance setup built right – from the beginning.
Systems only work if people trust them. Many companies can deliver parts of this puzzle. Strategy, ERP configuration, maintenance data or master data upload. Few can make it all work together.
We combine system expertise, data discipline, and operational understanding. We design maintenance systems around the people who will use them. A system is only sustainable if you get buy-in from the end-user - so we involve them early to ensure engagement, ownership and long-term value.
By aligning governance, systems, data, and people, we ensured the maintenance setup was both technically correct and practically usable.
