Reliability Academy

Case study · Oil refining

A large refinery complex in the GCC: an independent maintenance assessment across the whole complex

Reliability Academy won this maintenance efficiency assessment through open competitive tender, delivered a two-week on-site assessment across a large refinery complex in the GCC, and within weeks was invited back, as a keynote speaker at the client’s own reliability and asset management conference.

2 weeks

on site

Multi-plant

complex-wide assessment

~500 FTE

workforce in scope

The engagement

At a glance

Industry
Oil refining and petrochemicals
Location
Middle East (GCC)
Client
A large refinery complex, name withheld under a confidentiality agreement
Engagement
Maintenance efficiency assessment: consultancy, won via competitive tender
Timeframe
Contract commenced late 2025; a two-week on-site assessment in early 2026; final report issued early 2026
Scope
A maintenance execution workforce of roughly 500 people, with interviews from senior asset management leadership through to technicians and warehouse personnel
Oil refining & petrochemicalsMiddle East (GCC)Won via competitive tender

The problem

The challenge

The client operates a large refinery complex in the GCC: a large multi-plant refining and petrochemical complex, with a maintenance execution workforce of roughly 500 people. In late 2025 the organisation went to market for an independent assessment of its maintenance efficiency: how its planning and scheduling practices compared with industry best practice, how well its SAP PM and scheduling tools were being used, where execution was losing time, and whether its people and organisation were set up to plan, schedule and supervise work effectively. The brief was explicit: don’t just assess. Come back with concrete recommendations and an implementation plan across short, medium and long-term horizons.

Reliability Academy tendered in late 2025 and won the contract against established competitors.

The solution

What we did

The assessment ran in three parts. First, a desktop review of the client’s work management processes, KPI reports and twelve months of SAP work order data. Then two weeks on site in early 2026, where Erik Hupje attended the daily and weekly maintenance meetings across the plants as they actually happened (gatekeeping meetings, scheduling meetings, schedule lock-ins, execution coordination meetings) and interviewed personnel at every level, from senior asset management leadership to maintenance heads, planners, schedulers, supervisors, technicians and warehouse staff. Field observations and an execution delay study rounded out the picture of where time was actually going.

The findings were presented to site leadership in a close-out presentation in early 2026, before Erik left site, no surprises arriving by email weeks later. The final report followed in early 2026: a set of recommendations structured around a core work management improvement project, supported by specific technical recommendations and quick wins, each staged across short, medium and long-term horizons.

The outcome

The results

The assessment findings are confidential. They sit under a non-disclosure agreement, and so does the client’s name. That’s how it should be for an assessment of this depth.

What we can say is what happened next. Within two months of the report landing, the client’s central asset management team was using the assessment’s scoring framework to drive action planning at asset level across the complex. And the client invited Erik as a keynote speaker at its own reliability and asset management conference, scheduled for later in 2026: an invitation extended off the back of the assessment work, to present on world-class planning and scheduling to the client’s own people and peers.

When a client asks you to assess their maintenance function and then puts you on stage at their own conference, that says more than any metric we could publish.

What’s next

Assess your own maintenance function

If you want an independent, practitioner-led assessment of your maintenance planning, scheduling and execution, talk to us about a Reliability Academy site assessment, see how we work with teams.

See what this could look like for your team

A 30-minute call with Erik: your operation, your gaps, and whether this is the right fit. No pitch deck.