Increasing Yield & Reducing Energy Losses in an Ammonia Production Plant
- Fertilizer Production
- Mid-sized manufacturer operating a 20-year-old ammonia plant
- North Africa
Reducing Unplanned Downtime & Maintenance Costs in a Petrochemical Facility
- Petrochemical Manufacturing
- Large complex with ethylene, propylene, and polymer units
- Gulf Region
Obstacles Our Experts Have Transformed into Opportunities
A major Gulf-based petrochemical facility—was struggling with costly reliability issues:
Frequent Downtime
12 unplanned shutdowns per quarter, causing production losses of over $3M annually
Reactive Maintenance
Minimal predictive planning and no structured preventive maintenance
Inconsistency Across Shifts
Maintenance execution varied significantly between units and teams
Inventory Chaos
Spare parts were overstocked and poorly classified, delaying emergency repairs
No Criticality-Based Prioritization
Maintenance lacked a risk-based framework to prioritize efforts
Experienced, but Unstructured
Skilled engineers weren’t aligned under a unified, data-driven maintenance strategy
Teec’s Expert-Led Solution: Operations & Maintenance Excellence
Led by reliability and operations experts, this program established a sustainable and structured maintenance transformation:
What Our Experts Did
to realign maintenance strategies by risk
Introduced a customized Reliability-Centered Maintenance (RCM) framework tailored to failure modes
plans using live monitoring data
Built a Spare Parts Criticality Matrix to optimize inventory and reduce redundancy
Deployed a Maintenance Excellence Framework with clear KPIs, templates, and cross-functional ownership
This wasn’t just an improvement in execution—it was a complete cultural shift toward reliability and efficiency.
Execution Approach by Teec’s Experts
- Reviewed historical downtime records and emergency work orders
- Conducted walkdowns and planner interviews
- Performed a full Asset Criticality Analysis
- Aligned preventive tasks with real-world conditions and OEM guidelines
- Applied RCM logic to high-impact equipment
- Created checklists integrated into the site’s CMMS
- Audited stock for criticality, lead time, and duplication
- Built a Parts Prioritization Matrix to guide procurement
- Reduced unnecessary inventory and freed up working capital
- Delivered expert-led training on RCFA, FMEA, and Lean tools
- Introduced monthly “Maintenance Excellence Huddles” for accountability
- Created digital dashboards tracking:
- MTBF
- PM compliance
- Backlog aging
- Wrench time
- MTBF
Results & Impact
27% reduction in unplanned equipment downtime
30% fewer emergency work orders
$740K annualized savings in maintenance costs (parts, labor, recovery)
PM Compliance ↑ from 58% → 92% in just 3 months
Integrated Value Through Teec’s Data-Driven Solutions
Data-Driven Solutions
BPM Solutions
With TEEC’s expert integration of process, data, and digital tools, this facility transitioned from reactive to proactive—creating visibility, accountability, and sustained reliability.
