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Sector
Power and Utilities
Location
United Kingdom
Services
Reliability Consulting
Our partnership with Sellafield
Overview
A site equipment reliability model was developed to support the implementation of an integrated work management strategy. By delivering advanced maintenance equipment and technology selection, deployment and training, it was estimated that overall cost savings equated to £15 million.
We worked in partnership with Sellafield, a nuclear fuel reprocessing and decommissioning site based in the UK, to develop an equipment reliability strategy by identifying the sources of unreliability to implement strategies and a plan to remove or reduce them.
The challenge
A sufficient site equipment reliability model didn’t exist and had not been made available with the relevant knowledge and experience to effectively support the implementation of an integrated work management strategy.
The solution
The approach was to develop a central (ER) coaching team consisting of Sellafield and our engineers working together to:
- Establish a Technical Basis of Maintenance Reviews (TBoMs)
- Develop a site Condition Based Maintenance (CBM) strategy and implement across 23 facilities
- Deliver training to over 150 engineers
- Implement a site Asset Condition and Ageing Policy
- Perform risk-based inspection reviews
- Roll out TBoM/Asset Condition training to 200+ system engineers
- Deliver advanced maintenance equipment and technology selection, deployment and training
The result
The new site equipment reliability model resulted in a number of benefits, including:
Reduced SCC labour costs by £0.8 million: This was achieved by implementing a condition-based maintenance (CBM) strategy, which focuses on inspecting and maintaining equipment based on its condition rather than on a predetermined schedule. This resulted in fewer unnecessary repairs and downtime, which saved money.
An estimated overall cost saving of £15 million: This was achieved through a combination of the reduced SCC labour costs and other benefits, such as increased plant availability and reduced outage time.
Increased plant availability: This was achieved by reducing the number of unplanned outages, which allowed the plant to operate more consistently and efficiently.
A reduction in overall outage time: This was achieved by improving the planning and execution of maintenance activities, which reduced the amount of time that the plant was offline.
Effective deployment of resources: This was achieved by better understanding the needs of the plant and by allocating resources accordingly. This resulted in fewer resources being wasted and more efficient use of the available resources.
An increase in planned maintenance and work delivery: This was achieved by improving the planning and scheduling of maintenance activities. This resulted in fewer unplanned repairs and downtime, which saved money.
A reduction in the corrective maintenance backlog: This was achieved by prioritising corrective maintenance activities and by ensuring that they were completed in a timely manner. This reduced the risk of equipment failures and downtime.
Reduced supply chain costs: This was achieved by improving the procurement process and by negotiating better prices with suppliers. This saved money on the cost of spare parts and other consumables.
Overall, the new site equipment reliability model resulted in significant cost savings and other benefits for the nuclear company.
Key outcomes
Reduced SCC labour costs by £0.8m.
£15 million estimated cost-saving overall.
Increased plant availability.
Reduction in overall outage time.
Effective deployment of resources.
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