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We provide expert maintenance engineering consultancy, optimizing asset performance and operational efficiency.

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We deliver tailored maintenance training programs, equipping teams with cutting-edge engineering best practices.

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<h2 style="white-space:pre-line">Expert Maintenance Solutions</h2>
RPC Maint is a global provider of maintenance consultancy, training, and coaching services for manufacturing, process, and heavy industries. With expertise in maintenance management, we specialize in optimizing operational efficiency, enhancing safety, and extending the lifespan of critical equipment.
Our tailored solutions integrate industry best practices with innovative strategies to drive reliability and performance. At RPC Maint, we are committed to building lasting partnerships, delivering precision-driven results, and empowering organizations to achieve maintenance excellence.
If you do maintenance, we can help you!

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<h2>The Case for Post-TAR Evaluation </h2>A TAR is a complex, multi-disciplinary project involving thousands of tasks, contractors, and decisions. Given the high cost—up to $50M or more—and lost production impacts that can exceed $12.5M per day in an oil and gas facility, failure to evaluate turnaround performance in a structured and actionable way is not just an oversight, it’s a strategic misstep (Lenahan, 2006).Post-turnaround evaluation is a deliberate process of performance analysis, stakeholder feedback, and structured knowledge capture. It moves the organization from event-based execution to process-based learning. The objective? Drive improvements in safety, efficiency, cost control, contractor performance, and planning accuracy for future TARs.<figure id="figure-tc1mdd9xjama3rewom"><img id="tc1mdd9xjama3rewom" src="https://media.gettyimages.com/id/1426010228/photo/what-have-you-learned.jpg?b=1&amp;s=2048x2048&amp;w=0&amp;k=20&amp;c=ATGrNjtYNfGeDByscKoa94kOyISDOWtO4N54RHIPvAI=" alt="What Have You Learned?" title="What Have You Learned?" class="object-cover bg-gray-100 rounded-2xl md:rounded-3xl lg:rounded-4xl" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://media.gettyimages.com/id/1426010228/photo/what-have-you-learned.jpg?b=1&amp;s=2048x2048&amp;w=0&amp;k=20&amp;c=ATGrNjtYNfGeDByscKoa94kOyISDOWtO4N54RHIPvAI=" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure><h3>Core Components of an Effective Post-TAR Review </h3>1. Data-Driven Performance Assessment Success criteria should be measured against pre-defined objectives set during the strategic planning phase. These include:<ul><li>Safety metrics (e.g., LTIs, incidents, PTW compliance)</li><li>Budget adherence and cost control variances</li><li>Schedule fidelity (S-curves, critical path adherence)</li><li>Quality performance (QA/QC results, rework rates)</li><li>Contractor delivery vs. KPIs </li></ul>Accurate data must be gathered in real-time during execution, and should feed directly into the TAR Close-Out Report, forming the foundation for lessons learned and change management.2. Lessons Learned – From Theory to Practice Capturing lessons learned isn't about compiling a list of what went wrong. It’s about identifying systemic gaps and opportunities for transformation. This includes:<ul><li>Missed work due to poor scope definition</li><li>Recurrent safety risks stemming from inadequate training</li><li>Delays related to contractor underperformance</li><li>Overuse or underutilization of resources and equipment </li></ul>All findings must be converted into SMART actions—Specific, Measurable, Achievable, Responsible, Time-bound—and tracked through a formal change management process. This feedback loop ensures continuous organizational learning rather than repeated failure.3. Stakeholder Debriefing All stakeholders—plant managers, TAR coordinators, HSE teams, and contractors—should be debriefed shortly after completion. This provides critical feedback on organizational alignment, communication effectiveness, and leadership visibility during the TAR lifecycle. When structured correctly, this feedback identifies not just operational gaps but cultural issues that may impede future success.<figure id="figure-2qqqhyui6sma3ri9bg"><img id="2qqqhyui6sma3ri9bg" src="https://media.gettyimages.com/id/1147418228/photo/feedback.jpg?b=1&amp;s=2048x2048&amp;w=0&amp;k=20&amp;c=r2ILr068ca2wnzQ3PGEHCQI0tY4k51365RKBS_teZdM=" alt="Feedback" title="Feedback" class="object-cover bg-gray-100 rounded-2xl md:rounded-3xl lg:rounded-4xl" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://media.gettyimages.com/id/1147418228/photo/feedback.jpg?b=1&amp;s=2048x2048&amp;w=0&amp;k=20&amp;c=r2ILr068ca2wnzQ3PGEHCQI0tY4k51365RKBS_teZdM=" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure><h3>Embedding Continuous Improvement into the TAR Lifecycle </h3>Continuous improvement in turnaround management should not be reactionary; it must be embedded into the DNA of the TAR process. This requires a strategic pivot from episodic project thinking to a cyclical model of performance excellence.1. Institutionalizing Knowledge Knowledge must be institutionalized through standardized documentation and systems:<ul><li>Update TAR planning templates and work packs based on feedback</li><li>Refine contractor selection and pre-qualification processes</li><li>Calibrate future cost estimation models based on actual spend data </li></ul>Organizations should maintain a TAR Knowledge Management System, which becomes a repository of past experiences, enabling predictive insights and better risk mitigation for future events.2. Training and Competency Development One of the most undervalued aspects of post-TAR improvement is the impact on internal capabilities. Use performance evaluations to:<ul><li>Identify training needs across supervision, engineering, and planning teams</li><li>Build internal capacity through scenario-based training, particularly in SDSU logic and emergent work handling</li><li>Rotate high performers into mentorship or leadership roles in upcoming TARs</li></ul>3. Governance and Oversight Post-TAR evaluations must inform governance structures. Steering Committees should review close-out reports with the same rigor as pre-TAR budget approvals. This ensures accountability, reinforces a culture of continuous improvement, and prevents inertia or complacency.<figure id="figure-7p4fzpma5wma3rixb2"><img id="7p4fzpma5wma3rixb2" src="https://media.gettyimages.com/id/1196412786/photo/business-and-people-concept-senior-businessman.jpg?b=1&amp;s=2048x2048&amp;w=0&amp;k=20&amp;c=WfZiNlx_zxptyCpRNpLmPiL84I0XMU8ILvZZVeKiGK0=" alt="business and people concept - senior businessman" title="business and people concept - senior businessman" class="object-cover bg-gray-100 rounded-2xl md:rounded-3xl lg:rounded-4xl" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://media.gettyimages.com/id/1196412786/photo/business-and-people-concept-senior-businessman.jpg?b=1&amp;s=2048x2048&amp;w=0&amp;k=20&amp;c=WfZiNlx_zxptyCpRNpLmPiL84I0XMU8ILvZZVeKiGK0=" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure><h3>The Strategic Payoff </h3>Organizations that treat post-TAR evaluation and continuous improvement as non-negotiable components of their operational strategy will:<ul><li>Reduce cost and schedule overruns in future TARs</li><li>Minimize safety incidents and compliance risks</li><li>Strengthen contractor performance and commercial control</li><li>Build organizational resilience and competence </li></ul>As one industry leader remarked, “TARs are where reputations are made—or lost. But it’s what you do after the TAR that defines your trajectory.”<h3>Conclusion </h3>The TAR lifecycle does not end with demobilization. It ends with reflection, reform, and readiness. Post-turnaround evaluation is not merely a bureaucratic box-tick—it’s a business imperative. When embedded within a framework of continuous improvement, it becomes a strategic weapon that maximizes asset value, improves team effectiveness, and ensures each TAR performs better than the last.For progressive industrial operators, the message is clear: Evaluate relentlessly. Improve continuously. Succeed repeatedly.

10. Post-Turnaround Evaluation and Continuous Improvement

In today’s competitive industrial landscape, effective maintenance management is not just about fixing broken equipment—it’s about proactively ensuring operational efficiency, reducing downtime, and optimizing costs. Developing a robust maintenance strategy is critical to achieving these objectives. A well-crafted maintenance strategy aligns with business goals, integrates modern technologies, and leverages best practices to enhance asset reliability and performance.<h3>The Importance of a Maintenance Strategy </h3>A maintenance strategy serves as the foundation for asset management, helping organizations balance cost, efficiency, and reliability. As Sun Tzu famously stated, “Strategy without tactics is the slowest route to victory.” This principle applies directly to maintenance management—without a clear strategy, even the best tactics will yield suboptimal results. Companies with a well-defined maintenance strategy can improve equipment uptime by 20% (Reliabilityweb.com, 2018), resulting in significant cost savings and operational stability.<figure id="figure-19d9bgd5ym8rkd46y"><img id="19d9bgd5ym8rkd46y" src="https://media.gettyimages.com/id/1174513035/photo/books-of-compliance-and-regulations-in-front-grey-wall.jpg?b=1&amp;s=2048x2048&amp;w=0&amp;k=20&amp;c=Twex4pm9NOZLpJOnpPy7aBQNTJhjd4wmAjz9kbf0OB8=" alt="Books of Compliance And Regulations In Front Grey Wall" title="Books of Compliance And Regulations In Front Grey Wall" class="object-cover bg-gray-100 rounded-2xl md:rounded-3xl lg:rounded-4xl selected" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://media.gettyimages.com/id/1174513035/photo/books-of-compliance-and-regulations-in-front-grey-wall.jpg?b=1&amp;s=2048x2048&amp;w=0&amp;k=20&amp;c=Twex4pm9NOZLpJOnpPy7aBQNTJhjd4wmAjz9kbf0OB8=" data-mce-style="aspect-ratio: 16/9; object-position: center center;" data-mce-selected="1"></figure><h3>Key Components of a Successful Maintenance Strategy </h3>To develop a robust maintenance strategy, organizations must incorporate several key elements:1. Asset Criticality Assessment Before designing a maintenance strategy, organizations must identify their most critical assets. A structured approach, such as Failure Modes Effects and Criticality Analysis (FMECA), helps determine which assets have the highest impact on operations, safety, and costs. Prioritizing maintenance efforts based on asset criticality ensures optimal resource allocation.2. Selection of Maintenance Approaches Different maintenance strategies apply to different asset types and operational requirements. The four primary maintenance approaches include:Reactive Maintenance (Run-to-Failure): Suitable for non-critical assets where repair costs are lower than preventive interventions.Preventive Maintenance (PM): Involves scheduled inspections and servicing to reduce unexpected failures.Predictive Maintenance (PdM): Uses condition-monitoring technologies (e.g., vibration analysis, infrared thermography) to anticipate failures before they occur.Reliability-Centered Maintenance (RCM): A structured process to determine the most cost-effective maintenance approach based on asset functions and failure modes.<h3>3. Data-Driven Decision Making </h3>Modern maintenance strategies rely on data analytics and predictive insights. The use of Computerized Maintenance Management Systems (CMMS) and Internet of Things (IoT) sensors enables organizations to collect real-time asset performance data, reducing guesswork and improving maintenance planning.<h3>4. Workforce Training and Competency Development </h3>A maintenance strategy is only as effective as the team executing it. Investing in continuous training ensures that maintenance personnel stay updated on the latest tools, technologies, and best practices. Implementing skill development programs enhances workforce efficiency and reduces human-induced errors.<figure id="figure-gjpcdgefgum8rkia7b"><img id="gjpcdgefgum8rkia7b" src="https://media.gettyimages.com/id/1462085154/photo/workplace-safety-manual-with-work-equipment.jpg?b=1&amp;s=2048x2048&amp;w=0&amp;k=20&amp;c=affZRvuxOCgG87CpZBhPCMcefkLUCAQn0oseWDHGd8Q=" alt="Workplace Safety Manual with Work Equipment" title="Workplace Safety Manual with Work Equipment" class="object-cover bg-gray-100 rounded-2xl md:rounded-3xl lg:rounded-4xl" style="aspect-ratio: 16/9; object-position: undefined undefined;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://media.gettyimages.com/id/1462085154/photo/workplace-safety-manual-with-work-equipment.jpg?b=1&amp;s=2048x2048&amp;w=0&amp;k=20&amp;c=affZRvuxOCgG87CpZBhPCMcefkLUCAQn0oseWDHGd8Q=" data-mce-style="aspect-ratio: 16/9; object-position: undefined undefined;"></figure><h3>5. Integration with Business Objectives </h3>Maintenance strategies must align with broader business goals such as cost reduction, sustainability, and regulatory compliance. For instance, organizations adopting sustainability initiatives should incorporate energy-efficient maintenance practices to support environmental goals.<h3>Benefits of a Robust Maintenance Strategy </h3>A well-developed maintenance strategy offers multiple advantages, including:1.&nbsp; &nbsp;Increased Equipment Reliability: Regular inspections and predictive insights minimize unexpected failures.2.&nbsp; &nbsp;Cost Savings: Proactive maintenance reduces emergency repairs and unplanned downtime costs.3.&nbsp; &nbsp;Improved Safety and Compliance: Ensuring equipment is well-maintained reduces risks associated with malfunctions and regulatory non-compliance.4.&nbsp; &nbsp;Enhanced Productivity: A stable operational environment leads to better workflow efficiency and improved production output.5.&nbsp; &nbsp;Data-Driven Optimization: Leveraging analytics enables continuous improvement in maintenance processes.<h3>Conclusion </h3>Developing an effective maintenance strategy is a strategic investment that pays dividends in improved asset performance, cost savings, and operational reliability. By implementing a structured approach encompassing asset prioritization, data-driven decision-making, and workforce training, organizations can build a sustainable maintenance framework. As industries continue to evolve with advancements in digitalization and automation, organizations must remain agile and continuously refine their maintenance strategies to stay ahead of operational challenges.<figure id="figure-7sp7lid3n8m8rkl1gj"><img id="7sp7lid3n8m8rkl1gj" src="https://media.gettyimages.com/id/963443314/photo/support-button-on-keyboard.jpg?b=1&amp;s=2048x2048&amp;w=0&amp;k=20&amp;c=eUhvmuuU-wipnLxzEJA8eTenGJ3nDG6_WqPxiEBl4hg=" alt="Support Button on Keyboard" title="Support Button on Keyboard" class="object-cover bg-gray-100 rounded-2xl md:rounded-3xl lg:rounded-4xl" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://media.gettyimages.com/id/963443314/photo/support-button-on-keyboard.jpg?b=1&amp;s=2048x2048&amp;w=0&amp;k=20&amp;c=eUhvmuuU-wipnLxzEJA8eTenGJ3nDG6_WqPxiEBl4hg=" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure><h3>Call to Action </h3>RPC Maint specializes in helping businesses develop and implement effective maintenance strategies tailored to their operational needs. Whether you are looking to optimize asset performance, reduce downtime, or integrate modern maintenance technologies, our team of experts is ready to assist. Contact RPC Maint today to take your maintenance strategy to the next level. &nbsp; &nbsp; - **Hashtags**: #MaintenanceStrategy #Planning #OperationalExcellence

Introduction to Maintenance Strategy Development

In today’s competitive industrial landscape, organizations must relentlessly pursue operational efficiency to stay ahead. One of the most impactful methodologies to support this objective is Total Productive Maintenance (TPM). Grounded in the philosophy of proactive and preventive maintenance, TPM is designed to maximize equipment effectiveness and foster a culture of continuous improvement. As Mark Twain once said: "Continuous improvement is better than delayed perfection."<h3>What Is Total Productive Maintenance (TPM)? </h3>TPM is a holistic approach to equipment maintenance that aims to achieve perfect production: zero unplanned downtime, zero defects, and zero accidents. Unlike traditional maintenance strategies that rely solely on dedicated maintenance staff, TPM involves everyone in the organization—from operators to senior management—in maintaining and improving equipment.Developed in Japan in the 1970s and later adopted worldwide, TPM is built around eight foundational pillars:1.&nbsp; &nbsp; &nbsp;Autonomous Maintenance 2.&nbsp; &nbsp; Planned Maintenance 3.&nbsp; &nbsp; Focused Improvement 4.&nbsp; &nbsp; Quality Maintenance 5.&nbsp; &nbsp; Early Equipment Management 6.&nbsp; &nbsp; Training and Education 7.&nbsp; &nbsp; &nbsp;Safety, Health, and Environment 8.&nbsp; &nbsp; TPM in Administration Together, these pillars create a structured framework for sustainable performance enhancement across the entire operation.<figure id="figure-fa67y52xgrm92to2yn"><img id="fa67y52xgrm92to2yn" src="https://media.gettyimages.com/id/1817291034/photo/step-by-step-progress-blocks.jpg?b=1&amp;s=2048x2048&amp;w=0&amp;k=20&amp;c=4oaopvtee_ubsoJka3UA3d5rjc9HCLla2271gcx--YI=" alt="Step by Step Progress Blocks" title="Step by Step Progress Blocks" class="object-cover bg-gray-100 rounded-2xl md:rounded-3xl lg:rounded-4xl" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://media.gettyimages.com/id/1817291034/photo/step-by-step-progress-blocks.jpg?b=1&amp;s=2048x2048&amp;w=0&amp;k=20&amp;c=4oaopvtee_ubsoJka3UA3d5rjc9HCLla2271gcx--YI=" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure><h3>Implementing TPM: A Step-by-Step Approach </h3>Implementing TPM is a multi-phase journey that requires cultural transformation, cross-functional collaboration, and consistent management support. Key implementation strategies include:1. Top-Down Commitment Leadership must champion the initiative and allocate the necessary resources. TPM is not a one-off project; it is a long-term commitment to operational excellence.2. Initial Equipment Assessment Organizations must first identify existing inefficiencies and failure modes. This includes evaluating unplanned downtime, frequent repairs, and quality issues.3. Operator Involvement and Training Operators are trained to perform basic maintenance tasks such as cleaning, lubricating, and inspecting their equipment. This promotes ownership and enables maintenance teams to focus on more complex issues.4. Developing Maintenance Schedules Planned and predictive maintenance routines are established based on equipment condition and usage. The goal is to address issues before they escalate.5. Continuous Improvement Teams Cross-functional teams are created to address recurring problems using root cause analysis and problem-solving techniques like 5 Whys and Fishbone Diagrams.6. Performance Monitoring Overall Equipment Effectiveness (OEE) becomes the primary KPI, measuring performance, availability, and quality.<figure id="figure-h6hcqpz1agm92tw63e"><img id="h6hcqpz1agm92tw63e" src="https://media.gettyimages.com/id/1152357380/photo/quality-speed-efficiency-and-cost.jpg?b=1&s=2048x2048&w=0&k=20&c=3Wg65i-uyROSEtnH4jzavORi6JCXm9qcWNsNP-PCfjk=" alt="Quality, speed, efficiency and cost" title="Quality, speed, efficiency and cost" class="object-cover bg-gray-100 rounded-2xl md:rounded-3xl lg:rounded-4xl" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionX="undefined" data-positionY="undefined" data-fullWidth="false"/></figure><h3>The Impact of TPM on Overall Equipment Effectiveness </h3>TPM has a direct and measurable impact on Overall Equipment Effectiveness (OEE), the gold standard for asset performance. According to the Lean Enterprise Institute (2017), companies implementing TPM see an average 25% increase in OEE.Improvements include:o&nbsp; &nbsp; &nbsp;Higher Availability: Equipment is operational when needed, with fewer breakdowns. o&nbsp; &nbsp; &nbsp;Better Performance: Machines operate at optimal speed without slowdowns. o&nbsp; &nbsp; &nbsp;Improved Quality: Fewer defects and rework increase first-pass yield. These gains translate into:o&nbsp; &nbsp; &nbsp;Lower maintenance costs o&nbsp; &nbsp; &nbsp;Increased production capacity o&nbsp; &nbsp; &nbsp;Extended asset lifespan o&nbsp; &nbsp; &nbsp;Improved safety records Supporting this, McKinsey &amp; Company (2020) reported that advanced maintenance strategies like TPM can reduce maintenance costs by 20-30% and increase asset utilization by 10-15%.<h3>Common Challenges and How to Overcome Them </h3>Implementing TPM is not without its problems. Resistance to change, lack of training, and insufficient leadership support are common barriers. These can be addressed by:o&nbsp; &nbsp; &nbsp;Effective Change Management: Communicate the why behind TPM and celebrate early wins. o&nbsp; &nbsp; &nbsp;Tailored Training Programs: Upskill staff at all levels to build competence and confidence. o&nbsp; &nbsp; &nbsp;KPI Transparency: Use dashboards to track progress and demonstrate ROI. There will be bumps in the road as things won’t go as planned, things will change too slowly, or there will be unforeseen obstacles that will require addressing. The key is to keep focus on the goal, work the process, and be transparent.<figure id="figure-p4joj69pkcm92tuj4o"><img id="p4joj69pkcm92tuj4o" src="https://media.gettyimages.com/id/1269017110/photo/optimization.jpg?b=1&amp;s=2048x2048&amp;w=0&amp;k=20&amp;c=rN4_PzOMR1QQqAIMJ41ohxAl32AFO-hL0jtKzaw1nPI=" alt="Optimization" title="Optimization" class="object-cover bg-gray-100 rounded-2xl md:rounded-3xl lg:rounded-4xl" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://media.gettyimages.com/id/1269017110/photo/optimization.jpg?b=1&amp;s=2048x2048&amp;w=0&amp;k=20&amp;c=rN4_PzOMR1QQqAIMJ41ohxAl32AFO-hL0jtKzaw1nPI=" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure><h3>Call to Action: </h3>Total Productive Maintenance is more than a maintenance program—it's a culture shift that unlocks peak efficiency. At RPC Maint, we can help you in designing and implementing TPM frameworks tailored to your unique operational goals.Let us help you turn equipment reliability into a competitive advantage. <span style="font-family: inherit; font-size: calc(18px * var(--body-fontSize, 1)); font-weight: inherit; font-style: var(--body-fontStyle, normal); background-color: rgba(249,250,251,var(--tw-bg-opacity));" data-mce-style="font-family: inherit; font-size: calc(18px * var(--body-fontSize, 1)); font-weight: inherit; font-style: var(--body-fontStyle, normal); background-color: rgba(249,250,251,var(--tw-bg-opacity));">Partner with RPC Maint and start your TPM journey today.<span style="font-family: inherit; font-size: calc(18px * var(--body-fontSize, 1)); font-weight: inherit; font-style: var(--body-fontStyle, normal); background-color: rgba(249,250,251,var(--tw-bg-opacity));" data-mce-style="font-family: inherit; font-size: calc(18px * var(--body-fontSize, 1)); font-weight: inherit; font-style: var(--body-fontStyle, normal); background-color: rgba(249,250,251,var(--tw-bg-opacity));">#TPM #ProductiveMaintenance #EquipmentEffectiveness

Expert Maintenance Solutions

RPC Maint recent blog posts

10. Post-Turnaround Evaluation and Continuous Improvement

Introduction to Maintenance Strategy Development

Unlocking Efficiency: The Strategic Value of Total Produc...