This research addresses the critical challenge of the absence of an appropriate asset management system for district cooling applications. The primary objective is to design and implement a suitable and robust reliability improvement program specifically tailored to district cooling applications, ensuring it strikes the right balance between costs, risks, and asset availability. This research was conducted through two planned intervention cycles at a district cooling plant in Malaysia. Based on the findings of the gaps assessment, the first intervention cycle encompasses a series of strategic measures aimed at restructuring maintenance practices. These measures include redefining strategic reliability KPIs, refining key definitions for appropriate application, and redesigning preventive maintenance to incorporate condition-based maintenance (CBM) strategies. Building upon the successes of the first cycle, the second intervention cycle focuses on further refining the maintenance processes. This involves increasing stakeholder engagement frequency to enhance skills and reduce resistance to change. It also includes prioritizing impactful preventive maintenance activities according to available resources through Quarterly Maintenance Plan Review. Additionally, the implementation adheres to the Plan-Do-Check-Act (PDCA) framework to ensure continuous improvement in maintenance management. The interventions have resulted in tangible improvements in reliability, reduced equipment downtime, and enhanced accountability throughout the plant. The holistic approach adopted in this program emphasizes the importance of integrating various strategies and continuous improvement models to optimize operational performance. By successfully achieving the set targets, this reliability improvement program has demonstrated its effectiveness in elevating the performance and reliability of district cooling plants. The findings from this research provide valuable insights and practical recommendations for enhancing reliability and maintenance management in similar industrial settings.
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