Shell: Reducing maintenance costs through Hands on Tool Time (HoTT) optimisation

Reducing maintenance costs through Hands on Tool Time (HoTT) optimisation

Shell Nederland Chemie operates a large-scale, asset‑intensive chemical production site in Moerdijk with a complex maintenance organisation of both own employees and contractors. To keep maintenance costs under control and increase the effectiveness of planned maintenance, Shell focused on improving Hands on Tool Time (HoTT). PDM partnered with Shell to analyse maintenance performance, identify structural inefficiencies and optimise end‑to‑end maintenance processes. The result was higher productivity, improved predictability and a sustainable foundation for continuous improvement.

OUR CUSTOMER

Shell Nederland Chemie operates a large chemical production site in Moerdijk within a highly asset‑intensive and safety‑critical environment. Maintenance is executed by a combination of in‑house teams and contractors, requiring strong coordination, planning and performance management. Improving maintenance efficiency while safeguarding collaboration and safety was essential to control costs and ensure reliable operations.

THE CHALLENGE

Low Hands on Tool Time performance

Measurements showed that Hands on Tool Time for maintenance activities was significantly below the applicable WCM benchmark.

Limited predictability of planned maintenance

Low effectiveness of planned maintenance led to higher costs and the build‑up of maintenance backlog.

End-to-end process inefficiencies

Root causes of inefficiency were embedded across the full maintenance process, not limited to execution alone.

Maintaining collaboration with contractors

Improvements had to be realised without disrupting cooperation between Shell and its contractors.

Building excellence together

PDM analysed maintenance processes and HoTT performance to identify the structural causes of inefficiency. Based on these insights, maintenance processes were redesigned in close collaboration with the organisation.

Together with Shell, we introduced clear KPIs and a management structure to support daily steering and continuous improvement. This enabled the organisation to structurally increase HoTT while maintaining effective collaboration with contractors.

The impact we made

By optimising Hands on Tool Time and maintenance processes, PDM ensured that Shell achieved tangible and sustainable results.

33% increase in Earned Burned Ratio
Reduction of maintence backlog
Lower maintenance costs through better utilisation of people and resources
Improved predictability and control over maintenance planning and performance
A clear blueprint for future improvement initiatives

Facing Similar challenges?

PDM supports asset‑intensive organisations in improving maintenance efficiency, predictability and cost control by optimising end‑to‑end maintenance processes.

OUR APPROACH in action

We don’t optimise isolated activities. We improve the full maintenance system to deoliver sustainable performance gains.

HoTT and maintenance performance analysis:

In-depth analysis of maintenance processes and Hands on Tool Time performance to identify structural inefficiencies.

Process redesign:

Redesign of end-to-end maintenance processes to improve execution efficiency and planning effectiveness.

KPI and performance management structure:

Implementation of KPIs and management routines to enable daily steering and continuous improvement.

Collaboration with contractors:

Improvements realised while safeguarding effective cooperation between Shell and contractors.

Continuous improvement blueprint:

Creation of a repeatable approach to support future optimisation initiatives.

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