KPI-Driven Maintenance Planning for a District Cooling Plant

30% maintenance cost savings through data-driven asset management

Executive Summary

Our KPI-based Preventive Planned Maintenance (PPM) Planner revolutionized the client’s district cooling plant operations by minimizing equipment failures, extending asset life, and reducing unplanned shutdowns. Through proactive asset management, the solution delivered 30% annual maintenance cost savings, significantly improved plant uptime, and avoided major breakdowns—ensuring continuous availability and substantial reductions in repair, replacement, and manpower expenses.

Challenge

Before implementing our PPM Planner, the district cooling plant faced frequent equipment failures, unplanned shutdowns, and high maintenance costs. The lack of a structured maintenance schedule led to inefficiencies and increased the risk of critical failures, jeopardizing plant availability and reliability.

Solution Overview

We designed and implemented a comprehensive, KPI-based PPM Planner and Schedule tailored to the client’s district cooling equipment. Key components included:

✅ Daily Job Assignment: A full-year schedule assigning specific PPM tasks for each operational day, aligned with equipment criticality and KPI thresholds.

✅ KPI Driven Prioritization: Maintenance tasks prioritized based on asset performance metrics and risk profiles, ensuring critical components receive timely attention.

✅ Flexible Task Selection: The ability to refine daily schedules by selecting tasks based on available manpower, shifting priorities dynamically without compromising coverage.

✅ Real Time Monitoring Integration: Dashboards tracking task completion, failure rates, and maintenance compliance to facilitate continuous improvement.