Overview

A maintenance service provider faced vulnerabilities in internal processes following a safety incident at its site. This raised concerns about operational discipline and internal communication. While no major injuries occurred, the incident highlighted weaknesses in reporting, coordination, and compliance that could compromise future safety.

Approach

• Engaged site teams to map incident causes and process gaps.

• Reviewed safety logs and workflows, assessed causes and vulnerabilities, and analysed system and people behaviour against industry benchmarks.

• Recommended framework enhancements, safety program and incentives, and roadmap to foster good organisational behaviour.

• Developed metrics and KPI for team cohesion and performance.

Solutions Implemented

• Introduced a Safety Communication Framework with clear responsibility mapping across teams.

• Established awareness briefings and safety response training.

• Established incentives program to promote safety awareness and continuous improvement culture.

Results

• Boosted team synergy by 20% with better communication and agility.

• Improved response times by 25%, enhancing site operations.

• Reduced incident risks by an estimated 30% through proactive protocols.

Overview

A manufacturing plant faced inconsistent output, recorded repeated equipment failures and high downtime costs at an assembly line. The maintenance team struggled to implement an effective maintenance due to complex organizational structure, poor maintenance policies, inconsistent practices, and conflict in prioritization.

Approach

• Conducted interviews with plant personnel.

• Reviewed breakdown records (process lines, failed equipment, duration, frequency, and countermeasures).

• Assessed equipment criticality, ranks, and failure analysis with event probabilities.

• Presented maintenance strategies based on maintenance goals and weighted criteria (company priorities).

• Supported implementation of quick wins and a new framework.

Solutions Implemented

• Provided reference parameter values, improved installation procedures, guided skill assessment, and strengthened working instructions for operators, technicians, and maintenance team (Quick Wins).

• Established a structured maintenance framework to guide policy establishment, critical system selection, maintenance strategies, and decision-making.

• Guided initial implementation through training personnel on the new framework.

• Introduced preventive maintenance routines and a roadmap to enable proactive strategies like CBM for long-term gains.

Results

• Saved RM410k per year by cutting downtime costs.

• Reduced annual downtime by 30%, output stabilized at 94%.

• Improved maintenance decision-making by 40% through a clear framework, enabling plant readiness to adopt predictive maintenance strategy for ROI potential.

Overview

An expanding manufacturing company experienced recurring issues with asset transfers due to an outdated and poorly implemented procedure. The existing process lacked clarity, the transfer report template failed to suit operational needs, leading to untraced assets, frequent losses, and challenges in tracking movements. This resulted in rising costs from unnecessary replacements and weakened internal controls.

Approach

• Reviewed existing workflows, templates, and records against actual practices.

• Mapped out all possible asset movement scenarios (scrap, loan, trial, repair, user change, service).

• Recommended process redesigned and new standardised form with tracking number system and registry.

• Suggested immediate implementation with employee training and a trial period, followed by feedback for refinement.

Solutions Implemented

• Enhanced Asset Movement Procedure and introduced Asset Movement Form with tracking number system and monitoring registry.

• Conducted employee training and monitored implementation for effectiveness and refinement.

Results

• 30% reduction in asset loss incidents within 6 months.

• Improved asset traceability by 90% through formal documentation, registry, and tracking system.

• Streamlined requests by cutting the processing time by 70%.

• Cost savings achieved by reducing unnecessary asset replacements.

• Established an audit-ready and accountable process, strengthening internal controls.

Challenge

A chemical plant struggled with frequent equipment breakdowns, ineffective maintenance, and rising safety incidents. These led to low product yield, increased downtime, under-capacity operations, and escalating costs, threatening profitability and safety.

Approach

• Conducted structured interviews with plant personnel to identify pain points.

• Reviewed workflows, meetings, safety logs, and operational metrics (failure rates, costs).

• Benchmarked against industry best practices to highlight strengths and opportunities.

• Presented maturity profile to benchmark against industry best practices and highlight strengths and opportunities.

• Supported implementation of quick wins and digital tools for sustained impact.

Solutions Implemented

• Introduced Communication Management Plans → improved coordination.

• Developed Safety Programme + root cause analysis → reduced accidents.

• Shifted to a strategic maintenance approach with digitalisation → maximised uptime.

Results

• RM150k cost savings from maintenance costs within 1st year.

• Increased plant reliability with 97% plant uptime, 15% fewer breakdowns.

• 50% drop in accidents.

• Increased product yield to 44%, boosting capacity.

• Maximised ROI with 18% ROI secured for scalable growth.

Overview

Our client struggled with visibility and misplaced assets due to poorly maintained records and inconsistent workflows. The absence of a structured fixed asset ledger and proper tagging led to reporting gaps with Finance, misaligned records, and hindered operational efficiencies.

Approach

Audit:

• Conducted a full review of asset management workflows, comparing existing procedures against actual practices.

• Assessed data integrity (acquisition and financial records, plant layout) and in-house skills and tools.

• Recommended immediate actions and medium-term solutions as a foundation.

Implementation:

• Developed a fixed asset ledger with unique IDs and a framework for streamlined workflows.

• Introduced a cost-effective tagging system, later refined with supplier-provided custom labels.

• Conducted physical count and created location mapping with an in-house tool for clear traceability.

• Guided initial implementation with briefings, training, and demo within 6 months and a feedback cycle.

Results

• Fully furnished fixed asset ledger delivered within 3 months, enabling accurate monthly reporting.

• Achieved 90% asset tracking accuracy through ledger and tailored labeling.

• Enhanced operational efficiencies with cost-effectiveness through location mapping using in-house tools.

• Strengthened compliance and audit readiness through structured workflows and templates within 6 months.

• Established a robust framework, scalable and ready for ERP integration (long-term).