Rio Tinto Fer & Titane

Reverse RCM workshops and maintenance strategies aligned with plant reality.

Mandate duration: 14 months
Scope: Metallurgical complex — 4 critical areas
Pillar engaged: Maintenance strategies (reverse RCM)

Context

44% reduction in maintenance plan costs

A continuously operating metallurgical complex kept stacking preventive maintenance programs without ever challenging them. Crews executed tasks inherited from commissioning while the real failure modes had shifted with usage, process changes and successive modifications.

The problem

What we observed on the floor before the intervention.

Over 40% of preventive job plans with no demonstrated link to a real failure mode.
Repeat failures on critical equipment despite high maintenance volume.
Failure history barely usable: inconsistent coding in the CMMS.
Undocumented know-how concentrated in a few experienced employees.
Priority arbitration left to individual supervisor judgment.

Our solution

The approach deployed with the crews, from diagnosis to autonomy.

01Reverse RCM workshops facilitated with operators, mechanics and reliability engineers on the most critical assets.
02Formal criticality analysis and full review of preventive tasks: removal, merge, conversion to condition-based inspection.
03Rebuilt asset taxonomy and failure codes in the CMMS.
04Experienced employees' know-how documented directly into standardized job plans.
05On-site coaching of planners and supervisors on the new decision process.