Maintenance Transformation
A data-driven maintenance transformation business case for one of the world’s largest integrated energy complexes, converting SAP operational data into a quantified 5-year improvement program.
Location:
Saudi Arabia
Completion Date:
2026
Type of Work:
Asset Management & Maintenance Transformation
Energy & Utilities Client
Integrated Gasification Combined Cycle (IGCC) Power & Utilities
Problem
The client operates a major IGCC power and utilities complex in Saudi Arabia. Rising maintenance costs, low material availability and a growing work-order backlog highlighted systemic challenges across maintenance operations. Annual maintenance expenditure had reached SAR 1.575 billion, equivalent to 3.5% of replacement asset value, compared with a world-class benchmark below 2%.
Evidence
TDM conducted a quantitative AS-IS assessment using SAP data from 2023–2025. The analysis revealed 71% of assets with blank criticality, 99% misalignment in Min/Max levels, material availability of only 27% against a benchmark above 80%, and 58% of the 84,000-work-order backlog classified as aged.
The analysis demonstrated that these were not isolated issues. Weak asset criticality data cascaded into materials planning, availability, procurement and ultimately maintenance execution.
TDM Intervention
TDM translated the findings into a structured five-year maintenance transformation program. The engagement combined maturity assessment, SAP data analysis, industry benchmarking, bottom-up opportunity sizing and financial modelling.
The resulting roadmap comprised 47 projects across 14 initiatives, with project-level investment requirements, implementation phasing and three financial scenarios to provide management with a defensible basis for investment decisions.
Quantified Value
The business case identified SAR 936 million per year in addressable opportunity across six value pools. TDM developed a SAR 98.8 million transformation program with a base-case 7.4× ROI, representing SAR 731 million in benefits over five years.
Even under a conservative 30% benefit-capture scenario, the program was projected to deliver a 4.1× return, while supporting an improvement in maintenance maturity from 2.3 to 4.5+.
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