Building Operational Readiness for World-Class Maintenance

How a water utility built maintenance excellence and organizational readiness before commissioning a new advanced treatment facility.

Client:
Regional Water Supplier
Business Area:
Asset Management (AM)
Industry:
Critical infrastructure & Utilities
Location:
Denmark
Project details

Overview

Our client supplies tap water and treats wastewater for thousands of households. Their core mission is to ensure that their operations are running continuously and safely. They were building a new, highly advanced wastewater treatment facility that would:

  • Replace several older plants with one highly automated facility
  • Set new standards for treatment technology
  • Operate with minimal environmental impact 
  • Operate with world-class maintenance

The new plant’s technology was cutting-edge, but our client knew that achieving world-class performance required the same ambition for maintenance and operational readiness.

The Challenge: When high-tech meets traditional maintenance

The existing maintenance approach worked for the older plants. Experienced technicians who knew their plants inside out. Reactive maintenance when needed. Manual processes that had evolved over time. 

But the new facility required something new:

  • Automation and data-driven maintenance strategies 
  • Advanced treatment technology demanding specialised competencies 
  • High-performance expectations leaving no room for reactive approaches 
  • Integration across multiple complex systems

The gaps were clear:

  • No clear maintenance ambition for the new facility – What should world-class maintenance look like? 
  • Undefined requirements for sub-suppliers – How do we ensure contractors and OEMs deliver data and documentation we can use?
  • Unstructured asset hierarchy, tagging and documentation – Without clear structure, managing thousands of assets would become chaos.
  • Uncertain organisational readiness – Is the team prepared to maintain technology this advanced?

Without addressing these gaps, our client would potentially face downtime, inefficiency, and operational uncertainty. 

The Assignment: Defining the maintenance journey to world-class operation

Initially the assignment focused solely on the new plant, but it became clear that to succeed, we needed the existing organisation to be prepared. Culture, competencies, and processes across the entire organisation had to transform before the new plant opened. 

Our Approach: Engaging the entire organisation 

When we work with Asset Management, we always engage all levels: 

  • Frontline maintenance personnel who’ll be executing the work
  • Project organisation delivering the plant 
  • Top management setting the strategic direction 

Transformation only succeeds when everyone – from technicians to executives – understands the vision and commits to it. That’s why we don’t just consult your people. We work with them. Your frontline team brings irreplaceable knowledge of how things work in practice, and we make sure their knowledge shapes the solution from day one. 

Through structured workshops, hands-on working sessions, and close dialogue across all levels, we create the space for your people to be heard, to contribute, and to take ownership. We combine these insights with a systematic review of maintenance processes and governance to ensure that what we design together is not only analytically sound, but practically grounded and ready to be used.  

The result is improvements that your team has helped build, understands, and is motivated to sustain.

The Solution: A complete transformation roadmap

We stepped in to close the gaps. Not with advice alone, but by building the operational foundation the plant needed to perform. With clear requirements upfront, you get quality at handover. Data in compatible formats. Complete documentation package. In short, the asset was ready for stable operation and planned maintenance. 

Phase 1: Understand the current state 

  • Maintenance gap analysis of data structures and system governance 

Phase 2: Define requirements for the new plant 

  • Maintenance data and documentation specifications for suppliers
  • Asset tagging, hierarchy, and CMMS readiness

Phase 3: Enable supplier onboarding 

  • Practical master data and documentation templates 

Phase 4: Define future vision

  • Maintenance strategy aligning strategic goals with operations 

Phase 5: Assess organisation readiness 

  • Gap analysis of current practices, competencies, and culture 
  • Insight showed transformation must start in existing plants

Phase 6: Build the implementation roadmap 

  • Strategic Asset Management Plan (SAMP) with clear phases, system improvements and organisational development

What we delivered

  • Vision and strategy, including tender material for maintenance excellence and user requirement specification for CMMS
  • Maintenance maturity assessment 
  • Maintenance data templates
  • Impact and implementation management 
  • Strategic asset management plan (SAMP)

Results: A facility built to perform

Short-term: 

  • A clear vision and roadmap for maintenance maturity
  • Structured asset and data documentation templates 
  • Alignment across project and operations teams 

Long-term: 

  • A cultural shift toward proactive, data-driven maintenance 
  • Improved readiness for high-tech, automated operations 
  • Clear pathways for continuous improvement across the organisation 
  • Foundation for CMMS implementation and modern maintenance practices 

Let’s ensure your assets produce tomorrow, today.

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