1] With escalating production costs and shrinking margins, how can businesses embrace the asset maintenance and integrity culture?
Business’ should focus on marginal gains, through getting the basics right, focusing on getting the foundation data, such as having a fully comprehensive asset register and equipment criticality assignments that are correct, is a fundamental aspect and good starting point for encouraging a good maintenance and integrity culture. In our line of work we often see companies operating in a reactive mode, I would heavily encourage a shift to proactive maintenance programs through optimisation of the maintenance strategies and schedule, analysing historical maintenance data and failure trends, are proven techniques which have been found to encourage cultural changes, reduce maintenance expenditure and be a vital aspect of managing integrity - safe companies, who are in control, are efficient companies.
2] What solution/innovation do you feel will drive maximum growth in the Middle Eastern process safety industry?
My advice would be to focus on improvements in the capturing of asset data, including fail-safe, fail-to-danger analytics on Safety critical Equipment in order to determine probability of failure on demand, Improvements in MoC (Management of Change) through IoT (Internet of Things) and self-aware plant will lead to better control of change, statement of fitness and permit to work systems
3] How can organizations better integrate management of change (MoC) with their asset integrity & performance functions?
Good MoC will determine if there are like for like changes to plan or the introduction of new related risks as per the swiss cheese model. Poor MoC results in unknown equipment on site with no assurance tasks and no make/ model/serial number in the system to provide spares or replacements, resulting in periods of plant exposure where equipment is in a failed state, with a contingency in place in compliance with MOPO
4] How can organizations optimally leverage Computerised Maintenance Management Systems (CMMS)?
The CMMS should be an up-to-date record of the complete register of equipment with the criticality correctly assigned with assurance tasks in place to test the function of the equipment and reveal failures, it should help maintenance technicians not to precondition equipment and to record assurance values which determine whether the equipment was fail safe or fail to danger, it should be an audit trail for the number of tests and fails of SCE equipment to determine if the probability of failure on demand is met and the equipment is fit for purpose.