Digital Transformation Consulting

The client faced niche issues related to maximizing the efficiency, reliability, and sustainability of their long-term industrial assets, which typically operate for 30 to over 50 years. Specifically, they struggled with high costs associated with unplanned asset failures, with repairs costing 1.8 times more than preventative maintenance, and challenges in reducing downtime, optimizing maintenance activities, and ensuring safe, reliable operations over extended asset lifecycles. Additionally, they needed to improve workforce productivity through better access to real-time asset information, and to embed sustainability practices into their asset management strategy for responsible sourcing and energy reduction.

To address these challenges, tailored solutions involved integrating advanced digital tools such as AI-driven predictive analytics, digital twins, and connected device data to create a comprehensive and real-time view of asset performance. The client adopted an agile operating model that aligned corporate strategy with asset management functions, enhancing risk assessment, process efficiency, and real-time insights. They strengthened asset utilization by integrating Enterprise Asset Management (EAM) and Asset Performance Management (APM) systems, which streamlined workflows and set long-term performance goals. Workforce productivity was boosted by enabling field workers with accessible, real-time asset information via digital platforms, supporting safer and more efficient operations. Change management programs helped upskill employees to adapt to new autonomous and digital workflows.

Quantifiable results included increased production throughput through a reduction in asset downtime and unplanned maintenance, and significant maintenance cost savings via optimized preventive strategies. The client also built a more resilient and sustainable asset management foundation, contributing to longer asset longevity and improved safety standards. Additionally, by embedding smart routines and digital threads to trace asset lifecycle and origin, they advanced their sustainability goals and reduced energy consumption, aligning with industry shifts toward intelligent asset design, of which 70% of new investments are projected to fully incorporate by 2026.