A new iron-ore plant, given its full maintenance system before it ran a shift

A greenfield iron-ore operation was weeks from commissioning a new crushing and screening plant. The steel was built. The system to maintain it did not exist: no asset hierarchy for the CMMS, no routine tasks, no critical-spares list, no work instructions for the people about to operate it.

A plant that starts up that way runs blind. It discovers what needs maintaining when something stops, and reverse-engineers its master data out of failures during the worst possible window: the production ramp-up. The operator needed the maintenance framework in place before the plant ran, from the primary crusher to the final transfer station.

HolisticAM built the maintenance backbone first, as a desktop programme off a structured reading of drawings, P&IDs and OEM manuals. We registered every asset and component to maintainable-item level in a SAP-ready asset hierarchy, then built an RCM-based maintenance strategy: routine tasks built around how each asset fails instead of a generic OEM calendar, with lubrication and condition-monitoring schedules across five techniques on one aligned regime.

We developed an OEM-based critical-spares register and bills of material so procurement could stock the right parts before start-up, then wrote the work instructions: planned routine tasks grouped by asset, frequency, trade and operating status, plus five major-maintenance packs. In plain terms: we drafted the plant's entire maintenance system, then had the site crews validate it against real acceptable limits before handover.

• ✓A SAP-ready asset hierarchy to maintainable-item level, structured for direct upload.
• ✓An RCM-based maintenance strategy with lubrication and condition-monitoring schedules across five techniques.
• ✓An OEM-based critical-spares register and bills of material at maintainable-item level.
• ✓353 planned routine tasks plus five major-maintenance work-instruction packs, validated by the site crews.
• ✓A SAP-aligned work-management procedure and an initial three-year shutdown strategy.

Delivered as a 12-week desktop programme by two reliability engineers with principal oversight, across 23 in-scope asset lines from the primary crusher to the final transfer station.

Client de-identified at HolisticAM's discretion while commercial matters stand. Sector, plant configuration, scope and deliverable figures are drawn from the engagement's own scope, proposal and delivery records.