Case: Various customers, India (2014)

Optimized production through preventive maintenance


The customer's challenge

The outcome

Scope of supply

When HPCL entered an Annual Maintenance Contract (AMC) with Kosan Crisplant (today known as MAKEEN Energy) covering all its LPG cylinder filling plants in India, the positive effects were so evident that the rest of the country's major energy companies would soon follow suit.


Prior to the implementation of AMCs covering all the cylinder filling plants of the major players on the Indian market, the level of maintenance would vary immensely from plant to plant. Some would have a service agreement, others would use our services on a "break & fix" basis and others again would handle maintenance themselves.

Huge potential for optimization

However, as effective preventive maintenance is essential when it comes to the degree of utilization of electronic filling equipment, there was a huge potential for optimization of the production. And in a market with an annual growth rate around 8%, output is everything. The positive results achieved by HPCL because of the AMC have made the rest of the major players on the Indian LPG market follow suit so that the AMCs now cover five customers, 140 plants and 185 filling carrousels.

Higher uptime and protection of assets

By taking a preventive approach to maintenance, it has been possible to improve the uptime across all plants, simply by minimizing the amount of breakdowns and ensuring that the equipment is used optimally without ever being stretched to the limit. That latter is essential when it comes to extending the lifetime of the equipment.

Maintenance without production stops

Every service visit under the AMCs last two days. During the visit, our experts check the carrousel thoroughly and carry out the planned maintenance procedures. In order to minimize downtime due to service, the maintenance work is carried out on Sundays or public holidays. The following workday is used for monitoring the results of the work and carrying out whatever fine-tuning is needed.

Knowhow and experience

With 392,000 man-hours combined on the filling hall floor, the experience and knowhow of our India's team of service professionals are important reasons for the success of the AMCs. To further increase the consistency of their work across all plants, they rely not only on this vast experience, but also on a well-established framework for maintenance, developed by KC India (Today KC, Kosan Crisplant, is known as MAKEEN Energy). Training sessions for all staff levels ensure that the customers' organizations benefit from our experience in more than one way.

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