Asset Performance Management

Vidola Industry, a subsidiary of Vidola Titans Sdn Bhd, is a full-service Project Management (PM) or Project Delivery Partner (PDP) dedicated to the B2B sector. With 20 years of Industry experience, we are investing ourself into this market segment. We offer end-to-end solutions across various industries, including medium and heavy industries covering manufacturing and oil & gas. Our flexible approach allows us to either coordinate your chosen Nominated Sub-Contractors (NSCs) or leverage our own team of experienced subject matter experts to tackle your project challenges.

By partnering with Vidola Industry, you gain a trusted advisor who can guide your project from conception to successful completion, regardless of the chosen delivery model. We leverage our team of experienced engineers and industry best practices to deliver high-quality, customized solutions that meet your specific needs.

We manage the entire contracting lifecycle for procurement, ensuring you secure the best qualified bidders and negotiate the most favourable contracts. Our expertise extends beyond procurement to bridge potential skill gaps within your team.

While our mainstay services continue to be offered, Vidola Industry has solidified its expertise into 3 scopes which are maintenance strategic management, Facilities management and project management. Our collaborative approach ensures clear communication and effective change management. Vidola Industry doesn’t just deliver services or solutions; we deliver successes.

Vidola Industry understands the importance of a holistic approach. We believe in seamless project execution and collaborate effectively with our experts. We forged 3 core businesses.

Our maintenance & project management expertise is another key strength. We excel at integrating all aspects of your project and create a comprehensive master schedule that coordinates these activities, ensuring a smooth handover and efficient operation. We take full accountability to identify and mitigate potential risks that could impact operation, facilities management, and future maintenance activities, minimizing unforeseen challenges and disruptions.

Finally, our budget management considers not only for existing project cost  but also potential future maintenance needs, providing a more comprehensive financial picture. This integrated approach ensures a successful project outcome and sets you up for long-term success.

Maintenance Strategic Work

Vidola Industry offers a comprehensive array of services and expertise, organized into integrated service areas that covers every stage of the project lifecycle.

• Reliability Centered Maintenance (RCM)
• Condition Monitoring (CM)

• Reliability Centered Maintenance (RCM)

RCM is a systematic approach to evaluating and optimizing maintenance strategies for physical assets. The primary objective is to ensure that assets continue to perform their intended functions safely and efficiently. RCM involves a comprehensive analysis of failure modes, effects, and criticality, and it recommends appropriate maintenance tasks based on these analyses. The methodology for the best maintenance strategy is rooted in the principles of preserving system functions, identifying failure modes, and prioritizing maintenance efforts based on the impact of failure.

Instead of a single maintenance strategy, RCM is the optimal combination of reactive, preventive, predictive and condition-based maintenance. The advantage comes not from using these maintenance strategies independently, but by integrating them based on asset criticality and other failure management modes. Smaller assets that are non-critical are replaced with reactive maintenance while assets with random failure patterns or PM induced failures are maintained with condition-based maintenance. In this way, the best maintenance strategy is implemented.

• Goal of RCM

1. Boost asset performance: RCM enhances asset performance by optimizing maintenance strategies, thereby increasing reliability, decreasing downtime and reducing operational costs. Its approach leads to improved safety, sustainability, and overall asset effectiveness.
2. Cut down on costs: RCM improves workforce efficiency (reducing workload by cutting out unnecessary tasks), asset reliability and availability resulting in reducing costs.
3. Improve safety: RCM aims to understand the consequences of each failure mode and actively implement measures to prevent them. In addition to minimizing failures, the process of prioritizing maintenance also ensures the readiness of essential safety mechanisms.
4. Lengthen asset lifespan: It contributes to extending the lifespan of assets by focusing on proactive and optimized maintenance strategies. By identifying and mitigating the most critical failure modes, RCM enhances asset reliability and reduces the frequency of unplanned outages, thereby prolonging the asset’s operational life.

• Advantage of RCM

1. Cost Effectiveness
   RCM focuses on performing the right preventive activities, thereby reducing unnecessary costs. This approach minimizes both direct costs, like labor and parts, and indirect costs, such as downtime and lost production.
2. Promotes internal collaboration
   RCM fosters internal collaboration by involving multiple departments and stakeholders in the asset management process. It requires input from engineering, operations, maintenance, and safety teams to comprehensively analyze failure modes and determine the most effective preventive maintenance strategies. This collaborative approach ensures that all aspects of asset performance and risk are considered, leading to more informed and unified decision-making.
3. Improved Asset Reliability and Longevity
   By concentrating on the condition and criticality of assets, RCM enhances their reliability and extends their operational lifespan. This leads to fewer breakdowns, equipment failure and less unplanned maintenance, contributing to long-term cost savings.
4. Enhanced Safety
   RCM includes a thorough risk assessment component that identifies potential safety hazards. By proactively addressing these risks, the program contributes to a safer work environment.
5. Operational Excellence
   The systematic approach of RCM aligns maintenance activities with organizational goals. This results in improved performance metrics and contributes to achieving operational excellence.
6. Resource Optimization
   RCM allows for better allocation of maintenance resources. By focusing on critical assets and condition-based maintenance, organizations can deploy their manpower and materials more efficiently.
7. Compliance and Standardization
   RCM often leads to procedures that are in compliance with industry standards and regulations, making it easier for organizations to meet legal requirements and pass audits.

• Key Components of RCM

1. Risk Assessment: This is often part of the initial system selection and definition, as well as the failure effect analysis. Understanding the risks helps in prioritizing which assets or systems to focus on.
2. Failure Mode and Effects Analysis (FMEA): This is directly related to the Failure Mode Identification and Failure Effect Analysis steps in the RCM process.
3. Root Cause Analysis (RCA) : This can be integrated into the System Selection and Definition step, as well as during Failure Effect Analysis to prioritize failure modes based on their impact.
4. Preventive Maintenance Planning: This corresponds with the Maintenance Task Selection step, where preventive tasks are chosen based on the failure modes and their criticality.
5. Condition Monitoring: This is an ongoing activity that aligns with the Implementation and Monitoring step, ensuring that the state of assets is continuously or periodically assessed.
6. Performance Metrics: Key Performance Indicators (KPIs) are generally established during the Implementation and Monitoring phase to gauge the effectiveness of the RCM program.
7. Review and Adjustment: This is an extension of the Implementation and Monitoring step, ensuring that the RCM program remains effective and adapts to changing conditions.

• Methodology of RCM

1. Select equipment: Conducting an RCM analysis in all equipment can be cost prohibitive and too time consuming. The first step in implementing RCM is, therefore, defining the scope and selecting critical equipment.
2. Define functions: This is necessary to understand the operating context of the equipment. The functions and associated desired standards of performance.
3. Determine functional equipment failures: Determine every failed state possibility that will prevent equipment from fulfilling its desired function.
4. Determine Failure Modes and associated failure effects: Identify failure modes which are reasonably likely to cause each functional failure and determine the effects associated with each failure mode.
5. Identify failure consequences: The failure consequences vary depending on the asset and the impact on operations, safety and the environment.
6. Decide on: Based on your analysis, identify the maintenance tasks that will most effectively mitigate these failure modes.
7. Implementation and Monitoring: Time to put your plan into action. Implement the chosen maintenance tasks and keep a close eye on their effectiveness.
8. Change Management: This is not a separate step but should be seen as part of the entire process. Implementing RCM requires a new way of working which should be adopted by all important stakeholders.

• Four Pillars of RCM

1. Organizational change
   Organizational change is a critical pillar of a successful Reliability-Centered Maintenance (RCM) program for several reasons. First, the adoption of RCM often requires a shift in mindset from reactive to proactive maintenance strategies, necessitating organizational buy-in. Second, effective RCM implementation involves cross-functional collaboration, which can only be achieved through organizational alignment. Third, change management ensures that the workforce is adequately trained and equipped to adapt to new maintenance procedures and technologies. Lastly, organizational change facilitates the scalability of RCM maintenance programs, allowing for continuous improvement and adaptation to evolving business needs. This alignment with organizational change is essential for achieving measurable and sustainable improvements in asset performance.
2. Systematic Risk Management
   Kick things off with a deep dive into the risks tied to your assets and their potential failure modes. This is where a robust risk assessment comes into play, often as part of your Failure Mode and Effects Analysis (FMEA). It’s your roadmap for prioritizing which maintenance tasks need attention first. By getting a handle on the risks, you can channel your resources where they’ll make the most impact.
3. Data-Driven Decision Making
   Don’t just go with your gut; let the data guide you. Collect all the info you can get your hands on—operating conditions, past failures, performance metrics, you name it. This data-driven approach ensures that your chosen preventive maintenance tasks are both spot-on and effective. Plus, it sets the stage for establishing Key Performance Indicators (KPIs) to gauge how well your RCM program is doing.
4. Continuous Improvement
   Think of RCM as a marathon, not a sprint. It’s all about the long game, which means you’ve got to be committed to ongoing improvement and adept failure management techniques. Keep tabs on how your assets are doing, assess the effectiveness of your maintenance tasks, and tweak your plans based on what the data tells you. Regular budget reviews and adjustments are part and parcel of keeping your RCM program agile and optimized.

• KPI of RCM

1. Financial Metrics
2. Cost Savings: Measures the reduction in maintenance costs compared to a baseline period before RCM implementation.
3. Return on Investment (ROI): Calculates the financial gains relative to the total cost of the RCM program.
4. Operational Metrics
5. Equipment Availability: Measures the percentage of time that assets are available for use.
6. Mean Time Between Failures (MTBF): Calculates the average time between asset failures.
7. Mean Time to Repair (MTTR): Measures the average time taken to repair an asset after a failure.
8. Quality Metrics
9. First Time Fix Rate: Measures the percentage of repairs completed successfully on the first attempt.
10. Compliance Rate: Tracks the percentage of maintenance tasks completed in compliance with regulatory standards.
11. Safety Metrics
12. Safety Incident Rate: Counts the number of safety incidents related to maintenance activities.
13. Near Miss Reporting: Tracks the number of near misses that could have resulted in a safety incident.
14. Efficiency Metrics (OEE)
15. Work Order Completion Rate: Measures the percentage of work orders completed within a specified time frame.
16. Resource Utilization: Evaluates how efficiently resources like manpower and materials are used in maintenance activities.
17. Customer-Centric Metrics
18. Customer Satisfaction: Measures the level of satisfaction among internal or external customers who rely on the maintained assets.
19. Downtime Impact on Customers: Evaluates how maintenance activities and asset availability affect customer operations or experience.

• Condition Monitoring (CM)

Condition monitoring (CM) is a maintenance approach that predicts machine health and safety through the combination of machine sensor data that measures vibration and other parameters (in real-time) with state-of-the-art machine monitoring software. This approach enables plant maintenance technicians to remotely monitor the health of each individual piece of machinery and also offers a holistic, plant-wide view of mechanical operations.  Condition monitoring software sends an alert whenever a change is detected in machine health, enabling your maintenance technicians to immediately assess the situation and determine if corrective action is required.

   2.1) Goal & Advantage of CM

• Safety : plant personnel are saferand thus, we are all collectively safer.
• Time : Prevent unplanned downtime due to machine failure while simultaneously making the most of planned maintenance downtime by servicing multiple machines and addressing all known problems at the same time.
• Cost : Eliminates unnecessary—and wasted—costs associated with over maintaining healthy machines based on the static metric of operating hours alone.
• Quality : This true industrial maintenance tool, it is only just beginning to be leveraged effectively in a wider array of manufacturing industries. 

2.2) Methodology of CM

• Identify the critical equipment
• Identify type of sensors
• Identify type of data to be measured
• Monitor and understand your machine behaviour
• Vibration and position– Indications of dynamic and static motion of the rotor or machine case.An important part of analyzing vibration data and determining machine malfunctions. Machine vibration frequencies can show up as direct multiples or sub-multiples of the rotative speed of the machine.
• Temperature– RTD’s and Thermocouples measure the temperature of the machine’s radial and thrust bearings, lube oil, stator windings, and steam temperatures.
• Operating process sensors – these are typically already installed at the machine OEM level or as part of the process control system.  Pressure, flow , humidity & current values

2.3) Advantage of CM

• Increase Perfomance
• Informed Priorities
• Drive Focus on ROI

Today, only 3 to 5% of available data is being used to make important operational decisions. Digitalization is key to unlocking the vast amounts of untapped information embedded in your operation. Connect data, insights, and self-learning models across your entire operation to increase capital efficiency and profitability, decrease costs, and better allocate valuable resources.   

Anticipating machine failures before they occur, allows you to catalyze improvements that create positive ripple effects for the entire enterprise, such as:

• Minimize downtime, Maximize production  90% of failures are NOT time-based.  For many assets, failure can mean a substantial or total loss of production, often worth tens of thousands to millions per day. Often industries tend to focus on the larger, more expensive machines at the expense of ignoring the smaller supporting machines. Focusing on the machines that “make the money” is important but so too is focus on those machines without which the money-making machine can’t operate.
• Increase safety – Relying exclusively on hand-held devices for monitoring machine health can expose factory workers to unnecessary risks in our highly automated factories. Further, occasional catastrophic breakdowns due to maintenance gaps can increase employee exposure to hazardous conditions and potential environmental disasters.
• Reduce maintenance costs-When viewed on a per-asset basis, maintenance costs for plant-wide assets can appear modest. However, when viewed collectively across the dozens, hundreds, or even thousands of assets in a typical plant, these costs can be appreciable. Reducing the maintenance costs on each asset through effective condition monitoring—even by a mere 10%—has a large impact on plant profitability. Condition Monitoring is a planning tool that allows more effective insight in planning and asset management, allowing maintenance to be done in advance of a functional failure.
• Reduce hidden costs – Direct (traditional) maintenance costs are predictable and manageable. Indirect (hidden) maintenance costs, both stealthy and steep, can accrue to be up to 5X higher.For many plants, reducing these hidden costs is a mandate that requires us to shift from the traditional reactive approach (“fix it when it breaks”) to a proactive, reliability-based approach.

Scope

Specialized Engineering Design & Consulting Expertise

Vidola Industry’s engineers deliver comprehensive design and consulting services across all project stages from conceptualization to detailed engineering. We leverage industry best practices while injecting fresh perspectives to tackle challenges. This ensures high-quality, fit-for-purpose solutions through innovative engineering and detailed 3D modeling.

Added value:

• We efficiently grasp the core of your project requirements and standards. This lets us tailor design criteria to your specific needs, leveraging both your insights and current industry best practices.
• We offer ongoing support through troubleshooting, simulations, and optimization to ensure your existing facilities run smoothly.
• We collaborate with clients to define project scope and key milestones through clear documentation and design reviews to ensure accurate progress tracking and effective management of any changes.
• Across every project phase, from initial designs to final documentation, we continuously refine our processes and quality control measures.

Time

Thorough Planning, Scheduling & Time Management

We break down your project into manageable phases using a Work Breakdown Structure. This allows us to efficiently plan each stage, allocating resources and setting clear milestones to keep your project on track. A comprehensive project execution plan is then created to guide everything from kick-off to completion.

By investing in comprehensive upfront planning, we establish a strong foundation for project execution and success.

Added value:

Setting Up Your Project Schedule: What You Need To Know

• Project breakdown
• Material requirements
• Key project milestone
• Project deliverables
• Manufacturing & delivery plans
• Logistics and transport plan
• Construction plan and development
• Startup system identification

The sequence of interactions

• Structured activities guided by milestones
• Identifying critical dependencies based on experience
• Optimizing the sequence of engineering, procurement, construction, and commissioning across work packages, materials, areas, and systems
• Mapping dependencies between project activities.

Resource allocation planning

• Planning and securing resources for the project
• Employ histogram analysis for resource leveling in project scheduling.

Defining Project Timeline

• Production planning through market analysis for realistic project scheduling.
• Developing a schedule contingency plan through scenario simulations.

Project Execution Plan Development

• Identifying  the project’s bottlenecks
• Identifying potential cost changes associated with expedited delivery of critical items.
• Scheduling the project for realistic delivery based on scope and execution model.

Project Schedule Management

• Proactively assess the impact of potential changes before implementation, ensuring accurate forecasting.
• Tracking progress and predicting risks for proactive action
• Using Earned Value Management to track project budget and schedule performance
• Predict project end dates and identify potential scenarios by simulating the remaining work

Cost

Reliable Project Costing and Budgeting

Our budgeting process leverages past experience and ongoing engineering data to create accurate cost estimates throughout project phases. Estimates become increasingly refined as project plans solidify, with final adjustments made upon tendering and construction.

Added value:

Cost Estimating

• Leveraging the Work Breakdown Structure to define scope, track progress, and conduct reviews at the activity level
• The Cost Breakdown Structure (CBS) benefits from improved engineering estimates and up-to-date market data for procurement packages
• Centralized data enables versatile reporting and analysis
• Review summaries are created from the central database using pivot tables
• Clear data visualization drives informed decisions

Cash Flow

• WBS-based data capture ensures accurate estimates link to the project schedule, enabling reliable cash flow forecasting and financial models

Cost and Schedule Reserves

• Tracking foreign exchange costs per activity allows us to assess vulnerability to currency fluctuations
• Statistical software used to model cost variations and set allowances for uncertain base data.
• Allocate contingency based on risk severity and predicted likelihood during execution

Project Change Management

• Implement a change control process using the baseline budget, allowing for a precise assessment of any change’s impact

Cost Management

• Regular data collection ensures accurate cost control

Cost Tracking and Reporting

• Monthly commitments, cash flow, and forecasts are tracked to identify trends and intervene early for course correction

Efficient Procurement & Project Execution

Our expertise in procurement and contract management is integrated into the study phase, allowing us to develop effective contracting strategies from the outset.

We handle the entire contracting lifecycle, from service agreements and equipment procurement to tender documentation, adjudication procedures, and contract management.

Our services extend beyond procurement. We leverage our network of technical professionals to shield clients from skill gaps.

Added value:

Planning

• Partnering with clients to determine the most effective procurement strategy for their unique needs
• Creating a clear procurement management plan outlining the execution process

Enquiry process

• Identifying qualified bidders through a pre-selection process
• Negotiating contract terms to maximize value for each project
• Selecting the optimal contracting approach: fixed price, re-measurable, or time and material
• Leveraging a Procurement Management Plan to ensure successful procurement

Adjudication

• Selected optimal contractor for each project using a weighted evaluation matrix that considers capacity, capability, experience, and technical expertise
• Considering lifecycle costs, system integration, and operability
• Employment of comprehensive cost modeling to evaluate both direct and indirect project costs
• Actively guide clarification meetings and contract negotiations to secure mutually beneficial agreements for clients and suppliers

Contract Award and Management

• Contract management
• Proactive contract administration ensures on-scope delivery
• Aligning quantity surveys with progress reports
• Forefront risk management through expediting and delivery oversight
• Claims resolution
• Contract closure

Quality

Integrated Quality, Risk & Safety

Safety, Risk & Quality plans early are initiated, ensuring consistent application throughout the project.

Added value:

Our unwavering commitment to safety prioritizes a hazard-free environment throughout the entire project lifecycle. We achieve this by implementing robust practices like HAZOP reviews during design and ongoing task observations during construction.

By identifying and mitigating risks early on, we empower project managers and clients to make informed decisions. Our approach includes thorough risk analysis, developing mitigation strategies, allocating contingency resources, and maintaining an up-to-date risk register. This ensures project objectives are met through timely corrective action.

From planning to handover, we comprehensively apply quality control across all project aspects in management, engineering and procurement to consistently exceed expectations and meet agreed standards.

Our Team

At Vidola Industry, we understand that the key to successful projects lies in our team. We take pride in having assembled a team of highly skilled and experienced. We offer comprehensive training and certification programs throughout their careers, ensuring they possess the latest skills and capabilities to deliver exceptional results. We foster a collaborative work environment that prioritizes teamwork, high initiative, creativity, and a relentless pursuit of quality. These core values are embedded in our daily operations and guide our approach to every project. We deeply value our team’s contributions to Vidola’s success. We empower them through a results-oriented culture and a comprehensive reward system that recognizes and celebrates their achievements.