This document proposes a priority matrix to systematically assign priority levels to maintenance notifications at a Saudi Arabian facility. It aims to address issues like missed priorities that disrupted schedules and increased costs. The matrix defines four priority levels - Emergency, High-Urgent, Medium, and Low - based on factors like safety, production impact, and failure severity. Failure severity is categorized by issues like safety hazards, plant shutdowns, and equipment status ranging from already failed to very low risk of failure. The priority matrix seeks to build a strong, systematic process for priority assignment considering key concerns.

1. Priority Matrix Proposal

2. No. 1
Concern
Missus of Priority choosing authority was affecting the maintenance
process in terms of breaking the scheduled jobs and increasing the
overtime and expediting cost for Emergency and Urgent needs.
At the end of 2011 Saudi Kayan results was:
• Emergency Percentage = 6.97% Target < 5%
• Urgent Percentage = 42.1 % Target < 20%
• Preventive Maintenance Rate = 36.9 % Target 40~60 %

3. No. 2
Objective
To build a Strong & Systematic way for choosing notifications
priority considering Safety factors, Production Quantity and Quality
terms with keeping eye on minimizing maintenance cost.

4. No. 3
Defining Priorities
Emergency (P1):
* Failures that caused Health, Safety, or Environment Hazard.
* Failures that caused reduction in Production quantity or quality.
High – Urgent (P2):
* A condition which has the potential to cause Emergency situation.
Medium (P3) :
* Normal repairs that need to be planned and scheduled based on
resources availability.
Low (P4) :
* Minor activities which is required to improve the system/process.

5. No. 4
Identifying Priority based on Failure Severity
• Before choosing the priority, the failure severity should be segregated
to the following:
• Safety, Health, or Environment issue.
• Plant Complete Shutdown.
• Off Spec Production.
• Plant Partial Shutdown
• Equipment Shutdown.
• Other failures that will cause difficulty in operation.

6. No. 5
Identifying Priority based on Failure Severity
• Before choosing the priority, the equipment status should be
segregated to the following:
• Equipment already fail (breakdown)
• Equipment still running, but there is high possibility to fail within 24 hours
( expected to fail during the normal working hours or after that)
• Equipment still running, but there is a possibility to fail within 7 days.
• Equipment still running, but not expected to fail within 7 days.
• Equipment still running, and impossible to fail within 7 days.
• other requests that is required to improve the operating systems.

7. No. 6
Thank You