Functional Model of Integrated Maintenance (Reliability, Overall Equipment Effectiveness, Safety, and Cost) in Petrochemical Industries

In the petrochemical industry, effective maintenance management is critical to operational efficiency and safety. Key indicators such as overall equipment effectiveness (OEE), reliability, safety incidents, and maintenance costs are commonly used by management to evaluate maintenance system performance. Increasing equipment availability and product quality can boost OEE and lead to fewer safety incidents and improved overall performance. Studies in Iran’s petrochemical sector have shown that investing in maintenance and training can bring significant benefits. For example, data from 42 petrochemical complexes in Iran, covering 2015 to 2021, show an increase in equipment effectiveness and reliability over time. However, there was a slight slowdown in 2021 due to the impact of the Covid-19 pandemic. Improvements in maintenance performance, the use of excellence models along with the necessary training have been associated with increased product realization and productivity growth. Research also shows that increased reliability can positively impact the reduction of safety incidents, environmental issues, and overall operating costs. By prioritizing maintenance excellence and adopting best practices, organizations can strengthen their competitiveness and sustainability in a dynamic business landscape.