Kalmar Start-Up Services.
Be ready to go on day one.

Kalmar Start-Up Services.

Kalmar Start-Up Services guarantees the right people, resources and processes are in place to support your service and maintenance operations from day one. From large-scale terminal automation to specialist industrial projects, we will work with you to make sure your new operations start-up is a smooth one.

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Click on the process chart to see how we can help define your operational processes, service and maintainance needs and resource requirements.

Service & maintenance needs
Resources requirements.
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Operational processes
Exception handling
Health &
Service &
maintenance needs
Maintenance planning
Workshop planning
Inventory planning
Skill mapping

Identify your service and maintenance approach.

From our experience, the first task is to review your current approach to service and maintenance and compare it to your future requirements.

There are three different approaches to be taken into consideration. These are:

  • Corrective Maintenance: Repairs that are carried out once your equipment has broken down.
  • Preventative Maintenance: Pre-scheduled and specific maintenance tasks that are important to keep your equipment running.
  • Predictive Maintenance: Task scheduling is based on the historical analysis of your maintenance information. It identifies which tasks should be performed when to maintain maximum equipment uptime.

Once the right service and maintenance approach has been identified, a full service and maintenance strategy can be developed for your business.

Developing a maintenance task list.

This is a list of all the tasks that need to be completed to execute the chosen service and maintenance approach. It contains information about the man-hours, skill sets, tools and parts required to complete each task.

Identify your workshop requirements.

Workshop requirements are identified once the maintenance task list is completed. You will be able to see exactly what tools, equipment and parts are needed in the workshop to fulfill the identified maintenance tasks.

This will help to design the layout of the workshop, including washing bays as well as areas for oil separation and the handling of hazardous materials.

Planning your inventory levels.

Parts inventory requirements are identified once the maintenance task list is completed. You will be able to see which parts are needed to complete each maintenance task, and assess their criticality through a fault tree analysis of equipment. This will help set the precise inventory levels to keep your business running optimally.

As a part of inventory planning you will need to:

  • Know where to source the parts
  • Document the re-ordering process
  • Identify what parts will be held on site versus off-site
  • Agree delivery KPIs with parts suppliers.

Software management plan.

The software management plan will make sure your systems are running as expected and include the processes, policies and procedures for updates, testing, emulation, backups and the integration into other systems.

As part of overall software plan, the recovery and continuation processes will be defined to maintain critical operations if an unforeseen system interruption occurs.


It is important to define and document the processes for your chosen level of maintenance before the project becomes operational. In addition, the operational processes for exception handling, KPIs, health, safety and environmental strategies need to be documented.

Establishing your operational processes.

Once you have agreed your maintenance task list you can define and document the actions that need to be taken for each task. This will make sure that each task is completed efficiently and effectively.

Planning for exceptional circumstances.

Having a plan in place for handling exceptional situations is essential. The best way to start this process is to map out all the known exceptional scenarios that might occur. Next, develop the plan and processes on how to manage these situations.

Establishing your KPIs.

To ensure your maintenance team clearly understands the level of service they are expected to provide, a set of key performance indicators (KPIs) needs to be developed.

KPIs will define the criteria the maintenance team will be assessed against, as well as the methodology and tools used to make this assessment. It should also contain the KPI reporting frequency, in addition to evaluation and follow-up processes.

Health and safety strategy.

Health and safety strategy will help prevent accidents and injuries. This strategy needs to be developed in line with the health and safety regulations under which your business operates. Once the mandatory permits have been identified, you must ensure compliance with all their requirements.

Environmental strategy.

Operating safely and within local regulations and environmental guidelines is critical when maintaining equipment. Your environmental strategy needs to be documented, covering both risk assessment and the recovery process for any waste or hazardous materials that are handled while maintaining equipment.

Developing a resource plan.

Developing a comprehensive resource plan will ensure the right skills and resources are available in the right place for your business to operate effectively.

The resource plan should also identify the training required to build an appropriately skilled team.

Competence and skill mapping.

The required skills and competencies are defined in the maintenance task list. This includes identifying the right permits, licenses and certifications needed for each individual.

From this information, your personnel’s current skillsets can be compared against those required, and you can identify what additional training and qualifications are needed.

Resource and talent reviews.

Before recruiting new staff, it is important to identify the skills and competencies that are currently existing in-house. From this, you can perform a gap analysis; the skills you already have versus those that are required. This information will form a critical part of competency and skill mapping analysis.

Resource and talent reviews.

Before recruiting new staff, it is important to identify the skills and competencies that are currently existing in-house. From this, you can perform a gap analysis; the skills you already have versus those that are required. This information will form a critical part of competency and skill mapping analysis.

Training review.

From skill mapping analysis and expected staff turnover rates, you can identify the training or retraining your personnel will require. This allows you to develop a full training plan for the future.

Maintenance of Automated Terminals

Download our white paper “Maintenance of Automated Terminals”, which takes an in-depth look at what needs to be taken into consideration during a greenfield or brownfield project delivery so that your maintenance operations are running optimally from day one.

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