Solution

Maintenance Planning

Maintenance Planning

Tackling Maintenance Backlog with AI-Assisted Scheduling
Tackling Maintenance Backlog with AI-Assisted Scheduling
Screenshot of computer simulation
Screenshot of computer simulation

From backlog-driven firefighting to data-driven clarity — optimising maintenance schedules for higher crew utilisation and smarter resourcing.

Client(s)

Borregaard

Sector

Oil & Gas

Challenge

Maintenance Planning

Decision lens

Activity Planning

Product

-

Geography

Europe

The challenge

The challenge

In complex industrial plants, maintenance planners face an overwhelming puzzle every week: hundreds of work orders, crews with different skills and availabilities, and strict rules about which tasks can be done during stops or while equipment is running.


The result is long manual planning cycles, limited ability to test alternatives, and persistent backlogs. Leaders are left with tough trade-offs:


  • Push crews harder to reduce backlog, at the risk of deferring scheduled maintenance.

  • Increase crew size to execute more work - but at significantly higher cost.


Traditional planning methods make it hard to see these trade-offs clearly or adapt crew strategies week by week.

In complex industrial plants, maintenance planners face an overwhelming puzzle every week: hundreds of work orders, crews with different skills and availabilities, and strict rules about which tasks can be done during stops or while equipment is running.


The result is long manual planning cycles, limited ability to test alternatives, and persistent backlogs. Leaders are left with tough trade-offs:


  • Push crews harder to reduce backlog, at the risk of deferring scheduled maintenance.

  • Increase crew size to execute more work - but at significantly higher cost.


Traditional planning methods make it hard to see these trade-offs clearly or adapt crew strategies week by week.

Solution

We built an AI-assisted planning tool to bring structure and clarity to the maintenance planning process in a Norwegian refinery.


The tool integrates directly with SAP to import work orders, automatically prioritises tasks, and matches them against available crews and skills. Planners can:


  • Test different backlog horizons (e.g. 4 vs. 10 weeks).

  • Adjust crew size and skill mix dynamically.

  • Account for operational stops and resource constraints.

  • Generate alternative schedules in minutes instead of hours.


Results are presented in an intuitive interface: Gantt-style time views, crew utilisation charts, and completion percentages per work centre. This not only accelerates planning but also supports strategic discussions about backlog reduction and resourcing strategies.

Results

20–30% higher crew utilisation

compared to manual plans.

Reduced backlog risk

through transparent trade-offs between scheduled and overdue work.

Smarter resourcing strategies

by testing different crew compositions and sizes week by week.

Results

20–30% higher crew utilisation

compared to manual plans.

Reduced backlog risk

through transparent trade-offs between scheduled and overdue work.

Smarter resourcing strategies

by testing different crew compositions and sizes week by week.

Results

20–30% higher crew utilisation

compared to manual plans.

Reduced backlog risk

through transparent trade-offs between scheduled and overdue work.

Smarter resourcing strategies

by testing different crew compositions and sizes week by week.

Related solutions

Want to learn more about this solution? Get in touch and ask for a demo.

Want to learn more about this solution? Get in touch and ask for a demo.

Want to learn more about this solution? Get in touch and ask for a demo.

Want to learn more about this solution? Get in touch and ask for a demo.