Services
Maintenance planning and reliability engineering for process plants
We build and fix maintenance programs for water, desalination, mining and industrial plant: the strategies, the task lists, the spares, the planning and scheduling, and the investigations when something fails. The work is done by an engineer who has managed maintenance teams and shutdowns on operating sites, and it is delivered in your CMMS, ready to run.
Who we work with
Maintenance and reliability managers, plant managers and O&M contractors in Queensland, New South Wales and across Australia, and operators in the Gulf who need a maintenance program built or rebuilt without pulling their own people off the plant.
Problems we are asked to solve
- Maintenance is reactive and the preventive program was inherited from OEM manuals rather than built from how the equipment fails.
- Repeat failures on critical equipment with no structured root cause analysis.
- Spares holdings that do not match criticality: too much of the wrong stock and none of the right stock.
- Shutdowns that overrun because scope, planning and contractor coordination start too late.
- Work orders, backlog and history in the CMMS that nobody trusts.
What we do
- Maintenance strategy development using Reliability Centred Maintenance (RCM) and FMECA
- Preventive maintenance optimisation: task lists, frequencies, trades, durations and work instructions
- Work management: planning and scheduling processes, backlog clean-up, KPIs and weekly routines
- CMMS builds and data loads in SAP PM, Maximo, Infor EAM (VAMS) and MEX, including load sheets
- Root cause analysis and failure investigation using ICAM and Apollo methods
- Condition monitoring program set-up, review and audit
- Critical spares analysis and inventory optimisation
- Shutdown and turnaround planning, scope development and on-site coordination
- Contractor and OEM management, including maintenance contracts and warranty claims
- Maintenance analytics and reporting in Power BI
Recent work
- FMECA and RCM review of the maintenance and calibration program for three advanced water treatment plants, a 200 km pipeline network and its pump stations, with RPEQ sign-off, plus critical spares and high-voltage maintenance alignment for one of the plants.
- Complete maintenance build for a large beef processing plant in North Queensland: strategies, task lists, spares, work instructions and SAP load sheets, delivered as principal consultant with a specialist consultancy.
- Work management, condition monitoring and critical spares reviews, and on-site shutdown coordination, for three brine concentrators at a uranium mine in the Northern Territory.
- ICAM investigation of a DN1000 FRP pipe crack on the suction of a reverse osmosis high-pressure pump at a seawater desalination plant.
- Maintenance planning and scheduling support at a seawater desalination plant in New South Wales, and a sewage treatment plant maintenance build in Infor EAM for a gas plant in Western Australia.
Questions we are often asked
How long does a maintenance build take?
A single plant of a few hundred maintainable items typically takes six to ten weeks from site walk to CMMS load, depending on how much asset data exists.
Do you run the RCM workshops or just write the output?
Both. We facilitate the workshops with your operators, maintainers and OEM input, then write and load the result, so the program reflects your plant and your people own it.
Can you investigate a failure that has already happened?
Yes. We lead ICAM and Apollo root cause investigations, including the evidence collection, the analysis sessions and the report with corrective actions.
Turn maintenance from a cost centre into a plan
A 30-minute call is enough to scope most maintenance and reliability questions. No obligation.