Optimizing Maintenance Workflows in a Chemical Plant

Our client, a mid-sized chemical manufacturing company, faced frequent unplanned equipment downtime due to inconsistent maintenance procedures. Maintenance teams lacked clear, standardized workflows, resulting in delays, errors, and safety hazards. The client needed a solution to improve operational reliability and reduce maintenance costs.

Problem

The client encountered several critical issues:

• Maintenance teams across different shifts followed their own informal procedures, leading to inconsistent execution.
• Instructions for routine and emergency maintenance were unclear or incomplete, resulting in frequent errors and delays.
• Safety compliance suffered due to undocumented or poorly tracked maintenance activities.
• New maintenance staff required lengthy training periods because of the lack of standardized workflows and accessible knowledge resources.

Objectives

The project was designed to:

• Standardize and digitize all maintenance workflows to ensure uniform procedures across shifts and teams.
• Minimize errors and reduce the time taken to complete maintenance tasks.
• Enhance safety compliance by providing clear, auditable maintenance records.
• Accelerate training and onboarding processes through integrated digital resources.

Solution

ProcessNavigation delivered a comprehensive digital maintenance management system:

• Developed interactive, step-by-step Standard Operating Procedures (SOPs) accessible via tablets and smartphones, ensuring field teams always have the latest instructions.
• Implemented automated task scheduling and deadline tracking to hold teams accountable and prevent missed maintenance windows.
• Enabled real-time tracking of maintenance progress and equipment condition to support proactive interventions.
• Integrated training modules within the system to guide new staff through procedures and track their competency development.

Results

The client realized measurable improvements:

• Maintenance activities became more consistent and aligned with best practices, reducing variability in task execution.
• Unplanned equipment downtime significantly decreased, improving overall production stability.
• Safety compliance rates improved with detailed, time-stamped audit logs providing full traceability.
• New staff ramped up faster, reducing training costs and operational disruptions.

Conclusion

The digital overhaul of maintenance workflows transformed the client’s operational reliability. By standardizing procedures and enhancing visibility, the company minimized costly downtime and safety risks while fostering a culture of accountability and continuous improvement. The integration of training within daily operations also boosted workforce readiness, securing sustainable operational excellence.