Downstream Services - Behavior Change
To improve performance, first change behaviors
In asset-intensive industries such as chemical refining, some interesting statistics have emerged over time about the relative costs of Maintenance and Reliability efforts:
- Maintenance costs are typically between 15 and 40 percent of total production costs
- At least 30 percent of typical maintenance spend is simply wasted due to inefficiencies and ineffectiveness
- Breakdown repair costs average four times normal preventive maintenance costs, and can be as high as 15 times normal costs on an ongoing basis
- In refineries where 50 percent or more of maintenance activity is reactive in nature, craftsmen average two to three hours of “wrench time” per day, regardless of the amount of overtime being spent; contracted maintenance is a “mirror image.”
At MTG, we understand that Maintenance and Reliability are technical disciplines based on human behaviors. In order to make large changes in Maintenance and Reliability performance, we start by making small changes in the behaviors of individuals.
Major causes of business and functional performance issues:
- Human (behavioral) causes 85%
- Technological causes 12%
- Misfortune (bad luck) 3%
People and the way they behave on a day-to-day basis cause the vast majority of performance issues. At MTG, we do not believe that people come to work to do a poor job; rather, they simply act in ways that are unintentionally ineffective or inefficient due to numerous barriers. Only when everyone understands how an entire maintenance process works, can they truly understand their role in it and how to behave in order to address the barriers.
MTG designs and implements customized Maintenance and Reliability processes together with associated management controls and metrics, all designed to elicit and support the right behaviors.
Can your refinery do that?
