Mechanical Integrity: Development of Procedures, Work Processes, and Human Performance

The development of a mechanical integrity maintenance system is your next step if: a) your Risk Based Inspection (RBI) program has not been updated in a year; b) you are unsure if your report templates are complete; c) your KPIs aren not tracked; d) you are unsure where you are in the plan-do-check-update cycle; e) your people can use a refresher training course on your RBI technology, but you realize this is not a long-term solution; f) you want to align your work processes and procedures to ensure a sustainable best practice.
Mechanical Integrity: Development of Procedures, Work Processes, and Human Performance Improvement

The best maintenance systems are designed such that all elements work together as a quality system. If even one element is missing or poorly designed, the performance of the maintenance system suffers and is not as effective as it can be.

Asset Optimization Consultants designs mechanical integrity maintenance systems that account for each element, which improves the quality and sustainability of your RBI work processes and procedures. These improvements transform personnel, enabling them to embrace new processes and procedures and to develop discipline and effective behaviors in all circumstances.

The result is an enhanced culture of safety and performance with an effective, compliant, reliable operation.

Service Inquiry

Related Services

RAM, RCM, FMEA, FMECA and Bad Actor Analysis

AOC delivers the policies, procedures, work processes, knowledge and actions such as preventive maintenance, predictive maintenance, and condition monitoring tasks.

Mechanical Integrity Assessments

An interdependent assessment of your people, process, and technologies for a confident path forward

Risk Based Inspection (RBI) Implementation and Planning

AOC has delivered thousands of sustainable Risk Based Inspection (RBI) programs earning the trust of owner operators.

Related Tools

RBI Potential Savings Calculator

Create mechanical integrity (MI) program value rather than it being seen as a necessary cost to minimize.

Mechanical Integrity (MI) Compliance Checklist

Is your plant's MI program compliant? Use our checklist to assess your current program against industry standards and receive expert recommendations for improvement.

Related Training

RBI/MI Overview

A high level overview introducing Mechanical Integrity and Risk Based Inspection

GE APM Mechanical Integrity Work Process Training

How do I use GE APM to perform MI/RBI tasks?

Ensuring People Performance

How do I transfer knowledge to my team and verify their skills?

Risk Based Inspection (RBI) - A Mechanical Integrity Best Practice

What are your goals for RBI? How will you measure your success? How will you sustain that success?

The Learning Management Approach

Are your inspectors empowered to sustain your RBI program after the service provider completes their fixed price contract?

Related Knowledge

Achieving Unified Risk Management Through A Formal Acceptable Risk Policy.

A formal acceptable risk policy standardizes risk tolerance, assigns decision authority by risk level, and requires escalating approvals for higher risk, improving consistency, transparency, and resource prioritization while preventing unmanaged risk exposure.

Why is Management Of Change (MOC) so poorly executed?

MOC fails not from lack of knowledge, but from conflict with operational pressures. Speed is rewarded over rigor, definitions are unclear, ownership is weak, and risk reviews become procedural, allowing changes, cumulative risk, and hazards to go unmanaged.

What Good Refining Corporate Cultures Look Like

What does a strong refining culture actually look like in practice? Explore seven key attributes, from technical authority to management presence, that transform culture into a powerful risk-control system.

Unified Risk Framework Across MI, RCM, PHA, and SILSIS.

Unified framework integrating MI, RCM, PHA, and SIL/SIS into one risk-based system using a common matrix, shared failure modes, and closed-loop feedback to align actions, prioritize resources, and ensure consistent, real-world risk reduction.

Why Management Support is Key to "Good Inspection"

"Good inspection" is not defined by technical tools, but by a leadership choice to allow the truth about equipment condition to surface. Learn why management is the most critical variable in mechanical integrity.

How to practically implement RBI for oil and gas production.

Practical guide for implementing a Mechanical Integrity and RBI program for U.S. oil and gas wellfield, gathering, and midstream facilities. Aligns lifecycle asset management, inspection, and risk control with API standards, PHMSA pipeline rules, and OSHA PSM requirements.

How can I judge equivalent inspection techniques?

Organizations that follow the spirit of risk-based inspection rather than its minimum requirements use a definable, structured, auditable process to confirm that an alternate inspection technique provides equal or better risk reduction than a baseline method.

Can you improve reliability focusing on 3 priorities?

Safety-first organizations consistently outperform on reliability when priorities are truly enforced, not just stated.

Is Your RBI 3rd Party Qualified?

Don’t let your RBI program become a "paperwork exercise." Learn how to distinguish between a qualified technical partner and a software-only contractor to ensure true operational safety.

Plant Management 101: Common Work Processes

A dysfunctionality found in many refineries, chemical plants, and other production facilities, is a lack of common asset management work processes.