Customer Success Stories
Customers across asset intensive industries have already demonstrated that SOS
TM
and
RCM Turbo
TM
deliver measurable, repeatable improvements in reliability, cost control, and
decision quality. Below are featured organisations where these methodologies helped
them cut unplanned downtime, streamline maintenance workloads, and strengthen the
consistency of engineering decisions. By applying structured, business based processes
rather than intuition or legacy habits, teams have been able to prioritise the right work,
eliminate low value tasks, and build a more resilient maintenance culture.
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Customer Success Stories
Customers across asset intensive industries
have already demonstrated that SOS
TM
and
RCM Turbo
TM
deliver measurable, repeatable
improvements in reliability, cost control, and
decision quality. Below are featured
organisations where these methodologies
helped them cut unplanned downtime,
streamline maintenance workloads, and
strengthen the consistency of engineering
decisions. By applying structured, business
based processes rather than intuition or
legacy habits, teams have been able to
prioritise the right work, eliminate low value
tasks, and build a more resilient
maintenance culture.
Aluminium Bahrain
• Dedicated implementation of RCM Turbo over a three month period • Completed assessment of 75% of plant • Outcomes included 40% reduction in overall maintenance costs • Increased plant reliabilityColorado Power
• One Month pilot on Coal Handling plant • Outcomes included 56% reduction in planned maintenance costs • 20 major systems completed in 18 months • SOS use in one power station resulted in reduction of $ 4millionDelta Electricity
• SOS applied to manufacturers’ spares lists worth $900,000 (dry ash plant) • Optimised list using SOS less than $90,000Detroit Edison
• Fermi 2 Nuclear Plant - reduced spares inventory by $15million • $9.5 million directly attributable to SOS Hydro Quebec
• SOS applied to spares lists for new high voltage transmission equipment • Immediate saving - $795,000 • Total list $2.2millionLemington Coal
• Value of spares assessed using SOS - $2.2 million • 2,119 items assessed • Value of net reductions $ 504,000 • 22.9% reduction while optimisingRohm & Haas
• SOS project in one salt mine resulted in spares reduction while optimizing in excess of $US600,000Moura Mine
• RCM Turbo applied to Coal Handling Plant • Outcomes included annualised benefits totalling $1.5million • New equipment designs • Removal of ineffective maintenance tasksNewcrest Telfer Mine
• SOS applied to manufacturers’ spares lists during RCM Turbo implementation • Immediate benefits, one site, one list over $94,000NZ Aluminium Smelters
• SOS applied to spares list for new pot line • Immediate benefit - $700,000 savings on list worth $1.4millionPacificorp Generation
• Used SOS to reduce generation spares from $68million to $54million • $14million benefitPortland Aluminium
• SOS directly responsible for spares optimisations valued at $1million • Original value $5.7million total reduction 33%Proton Malaysia
• Value of spares assessed using SOS $1.98million • Optimised reductions $807,000 • 40% improvementPt. Waratah Coal
• Applied RCM Turbo to their conveying systems as part of a pilot • Implemented outcomes immediately • After 12 months, achieved virtual elimination of breakdownsQueensland Nickel
• SOS used for optimisation of fast moving items - Min/Max levels • Slow moving items - cost/risk assessment • Redundant items identified • 55.7% of stock optimised for 10.8% identified reduction in store $ value.Queensland Nitrates
• When a greenfield site - new spares lists totalled $2.49million • SOS optimized lists valued at $ 1.25 million • Saving $ 1.24 million • Acquired RCM Turbo in 2018Snowy Mountains Hydro
• Using RCM Turbo reduced routine planned maintenance costs by 30% • Reduction in maintenance costs for generation assets - 25% • Increased generation availability • Initial exercise at Murray 2 Station - eight months durationSt Ives Gold Mine
• SOS applied to manufacturers’ spares lists • Immediate benefits, one site, one list over $120,000Tampa Electric
• SOS applied to 450 items over $100 • Total value of these $ 434,000 • Net reduction $ 217,245 • 50% reduction after increases of $7,300Tarong Coal
• RCM Turbo applied to dragline • Outcomes included reduction of 4000 hours in maintenance manhours • Direct labor cost savings $350,000 • SOS applied to dragline spares • Outcome - reduction in total spares inventory of $1,500,000 • Annual improvement $450,000 • Indirect additional savings $ 250,000Tarong Energy
• World record continuous operation of Generation Unit 2 - during 2001 • RCM Turbo recognised in Tarong Energy’s Annual ReportTennessee Valley
Authority
• Using SOS as part of a five year plan to reduce overall spares by $100 million • At the beginning of year 5, accumulated reductions exceeded $94 millionTioxide Malaysia
• Results from pilot - 223 items assessed using SOS • Value of spares assessed - R3,226,000 • Value of spares reductions - R 617,000 • 19% reductionWater Corporation WA
• Statewide implementation of RCM Turbo • Quantified benefits exceeding $2 million • Special case of Kununurra Dam - improvements worth $700,000 in that one site aloneWeyerhaeuser Timber
• Established standard interval for review of MTBF’s and revisions of PM inspections. • Increased maintenance uptime from 85% to 98% consistently. • Increased utilization from 60% to 82% consistently. • Reduced maintenance overtime from 20% to 11% consistently.
