Maintenance and Reliability Management
Reduce downtime and backlog, improve availability, and make shutdowns more controlled
Rayterton Maintenance and Reliability combines asset registers, preventive maintenance, end to end work order lifecycles, shutdown and turnaround planning, and reliability analytics (MTBF and MTTR). The focus is stable operations, controlled costs, and audit ready maintenance history.
What management wants to control
Downtime is expensive. What matters: availability, backlog, and shutdown readiness.
Maintenance issues that most often drain margins
Downtime is often not purely technical. It happens when backlog is not visible, PM is not disciplined, spare parts are not ready, and failures repeat without analysis. This system locks the process from request to closeout.
Backlog is visible and prioritized
Priority based on criticality, risk, and production impact, not just first in line.
Consistent preventive maintenance
PM schedules, checklists, and compliance by equipment, including overdue alerts.
Repeat failures must stop
A failure registry and analysis help break recurring failure patterns.
Core capabilities
Suitable for refineries, terminals, pipeline stations, upstream field facilities, rotating equipment, and utilities.
Work Order Lifecycle (Request to Plan to Execute to Close)
All work is logged, prioritized, and closed with evidence so history stays clean and analyzable.
- ✓Work requests with classification and criticality
- ✓Planning: scope, labor, duration, tools, permits (optional)
- ✓Execution logs: time, notes, attachments, parts used
- !Overdue and escalation for critical work
Preventive Maintenance (PM) and Compliance
Clear PM schedules, standardized checklists, and compliance status by unit or site.
- ✓PM templates: checklists, methods, safety notes
- ✓Auto generated work orders from PM schedules
- ✓PM compliance dashboards: due, done, overdue
- !Deferral governance (optional): defer PM with approval
Shutdown and Turnaround (TAR) Planning (Optional)
Structured shutdown workpacks: scope, schedule, resources, critical paths, and readiness checklists.
- ✓Shutdown scope registers with priorities
- ✓Workpacks: tasks, materials, permits, QA checks
- ✓Readiness dashboards: open vs ready
- !Post shutdown reviews: delay causes and lessons learned
Spares and Materials Visibility (Optional)
Work often fails because parts are not ready. This module aligns parts requirements with work orders.
- ✓Parts reservations for work orders
- ✓Critical spares registers (optional)
- ✓Stockout risk lists (optional)
- ✓Integration ready with inventory and ERP
Maintenance and Reliability Modules (Modular)
Start with work orders and PM, then expand into reliability analytics, shutdown management, and parts visibility.
Asset Register and Equipment Hierarchy
Tagging, hierarchy, criticality, locations, and maintenance history by asset.
- ✓Equipment structures by area or unit
- ✓Criticality scoring (optional)
- ✓Document repositories (optional)
Work Requests and Prioritization
Requests captured with classification, priority rules, and routing to planners or supervisors.
- ✓Priority matrices
- ✓Auto routing
- ✓Approvals (optional)
Work Order Planning and Scheduling
Scope and schedule planning, including resources and estimated durations.
- ✓Planner workbenches
- ✓Labor and skills (optional)
- ✓Schedule views
Execution, Time Logs, and Closeout
Execution notes, parts used, downtime capture, evidence, and closure approvals.
- ✓Technician execution logs
- ✓Downtime capture (optional)
- ✓Attachments and closure evidence
Preventive Maintenance (PM)
PM templates and schedules with compliance dashboards and alerts.
- ✓PM templates and checklists
- ✓Auto work order generation
- !Overdue PM alerts
Reliability KPIs and Analytics
MTBF, MTTR, availability, repeat failures, and top downtime drivers.
- ✓MTBF and MTTR trends by asset class
- ✓Top downtime causes
- ✓Bad actors list (worst performers)
Failure Registry and RCA (Optional)
Failure modes, analysis, and permanent actions so failures do not repeat.
- ✓Failure mode catalogs
- ✓RCA workflows (optional)
- ✓Actions linked to work orders and PM updates
Shutdown and Turnaround (TAR) (Optional)
Scope registers, workpacks, readiness checklists, and post TAR reviews.
- ✓Workpack management
- ✓Readiness dashboards
- ✓Lessons learned
Parts and Materials Visibility (Optional)
Parts reservations for work orders, critical spares, and stockout risk lists.
- ✓Parts reservations
- ✓Critical spares registers
- ✓Integration ready to ERP
Example "wow" screens for the Director of Operations
Placeholders for screenshots and mockups. Focus on backlog, downtime, and shutdown readiness.
Maintenance Command Center
Backlogs, overdue work, critical work orders, and bottlenecks by area or unit.
Reliability Dashboard
MTBF and MTTR, availability trends, and a bad actors list to power reliability programs.
PM Compliance Scorecard
PM due, done, overdue, deferrals, and compliance by area.
Shutdown Readiness Cockpit
Workpacks ready, materials readiness, permits, and critical path status.
Governance, audit trails, and integration
Maintenance history must be trustworthy and usable for analysis. This system provides audit trails, approvals, and integration readiness.
Role Based Access
Permissions by role: requester, planner, supervisor, technician, management.
Approvals and Change Logs
Work order and PM changes, deferrals, and closure approvals are logged.
Integration Ready
Exports or APIs for integration with ERP, inventory, HR, and other systems.
Phased implementation that delivers impact fast
Start with work order and PM discipline, then add reliability analytics and shutdown readiness, followed by parts integration and RCA.
Phase 1: Work Orders and PM Discipline
Quickly control backlog, overdue work, and compliance.
- ✓Asset registers and work order lifecycles
- ✓PM templates and scheduling
- ✓Backlog and PM scorecard dashboards
Phase 2: Reliability, Shutdowns, and Spares
Move into management level control: reliability programs and shutdown readiness.
- ✓MTBF and MTTR analytics and bad actors
- ✓Shutdown and turnaround workpacks (optional)
- ✓Parts reservations and critical spares (optional)
Want a maintenance demo focused on backlog control and reliability KPIs?
We can prepare a demo: work order lifecycle, PM scheduler, backlog cockpit, MTBF and MTTR analytics, and a shutdown readiness dashboard.