CMMS for Petrochemical Plant - SABIC Jubail

SABIC's Jubail petrochemical facility managed 3,000+ rotating and static assets using paper-based work orders and spreadsheet tracking. Maintenance teams had no visibility into equipment health, leading to reactive maintenance that caused an average of 18 hours of unplanned downtime per month. Spare parts inventory was poorly tracked, resulting in 12% emergency procurement at premium costs. The plant needed a modern CMMS that would integrate with their existing SAP PM module without disrupting established workflows.

SKYLINE deployed a comprehensive CMMS platform with full asset hierarchy mapping for all 3,000+ assets, preventive maintenance scheduling based on manufacturer recommendations and historical failure data, IoT vibration and temperature sensors on 200 critical rotating equipment with real-time anomaly detection, mobile work order management for field technicians via tablets, automated spare parts reorder triggers based on minimum stock levels, and bi-directional SAP PM integration syncing work orders, costs, and asset records. The rollout followed a 3-phase approach: data migration and configuration, pilot on one production line, and full plant deployment.

Unplanned downtime reduced by 42% within the first 6 months — from 18 hours/month to under 10.5 hours/month. Preventive maintenance compliance reached 94%, up from 61%. Emergency spare parts procurement dropped from 12% to under 3%. The IoT predictive monitoring system detected 23 potential failures before they occurred in the first quarter alone, preventing an estimated SAR 2.1M in production losses. ROI was achieved within 8 months of go-live.