Rio Tinto Fer & Titane

Maintenance cost optimization through a full review of maintenance strategies.

Mandate duration: 10 months
Scope: Critical areas of the metallurgical complex
Pillar engaged: Maintenance strategies

Context

2.3M$ in recurring maintenance cost savings

The complex's maintenance plan had grown for decades without ever being challenged. Every incident added a task, none were ever removed. The maintenance budget climbed year after year with no measurable availability gain: the sign of a plan working against itself.

The problem

What we observed on the floor before the intervention.

Legacy maintenance plan, never revised: redundant tasks, arbitrary frequencies, intrusive work on stable assets.
Recurring cost in hours and parts with no demonstrated link to a real failure mode.
Planned outages lengthened by low-value preventive tasks.
Specialized resources tied up on non-critical equipment.
No way to cost the maintenance plan equipment by equipment.

Our solution

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

01Full costing of the existing maintenance plan: hours, parts, contracting and associated downtime, per equipment.
02Joint operations-maintenance-HSE criticality analysis to rank assets by real impact.
03Systematic strategy review: removal, frequency reduction, job plan merging, conversion to condition-based inspection.
04Retained job plans rebuilt with standard times, parts and tooling.
05Before-after gain calculation, embedded into the maintenance budget to lock in the recurring saving.
06Planner coaching so the review becomes an internal annual cycle.