Digital RFID-based system leads maintenance transformation that reduces NPT, boosts HSE
Pertamina Drilling Services Indonesia sees planned maintenance compliance rate rise to 97% while eliminating major equipment failures

By Slamet Nurhadi, Pertamina Drilling Services Indonesia
In the rapidly evolving energy sector, companies face increasing pressure to enhance operational efficiency, safety and reliability. Pertamina Drilling Services Indonesia recognized the urgent need for a transformative approach to maintenance management. This awareness sparked the journey toward implementing an RFID-based digital maintenance system (DMS) that utilizes a reliability-centered maintenance (RCM) strategy.
This article explores the challenges faced, the innovative solutions implemented and the improvements achieved through this digital transformation.
The challenges
Before implementation of the DMS, Pertamina Drilling Services Indonesia grappled with several critical challenges that hindered operational effectiveness. The reliance on manual maintenance processes resulted in extensive reporting that was both time-consuming and prone to errors. Technicians would often spend a significant amount of time documenting maintenance activities instead of focusing on actual equipment upkeep. The lack of effective tracking mechanisms for maintenance records made it difficult to identify trends and proactively address potential issues, ultimately increasing the risk of major equipment failures with serious safety implications.
Furthermore, the company recognized an opportunity for improvement in the execution rate of planned maintenance, which was relatively low. This was primarily due to time constraints and the limited human resources available compared with huge maintenance tasks to be carried out.
The cumulative effect of these safety and operational challenges translated into significant financial losses, as downtime affected productivity rates and incurred high costs associated with manual documentation processes. The inability to access real-time data also hampered decision making, leading to delays in addressing maintenance needs and exacerbating operational challenges.
Root cause analysis
To develop a solution, the company conducted a thorough root cause analysis that revealed four primary contributing factors to the challenges faced. The most significant was a technology gap, accounting for 57% of the challenges encountered. It became clear that outdated data-processing tools forced the company to rely on manual record-keeping, while poor real-time monitoring capabilities and fragmented data storage compounded the issue. This technological inadequacy not only hindered operational efficiency but also limited the ability to leverage data for informed decision making.
Process inefficiencies, which accounted for 31% of the challenges, arose from traditional documentation methods that were cumbersome and inefficient. These methods created bottlenecks in information flow, limiting data accessibility for personnel and delaying response times to maintenance needs. The reliance on paper-based records often resulted in misplaced documents and inconsistencies in data, further complicating the maintenance process.
Data management challenges, comprising 7% of the issues, stemmed from inaccuracies that undermined the reliability of maintenance records. These inaccuracies complicated informed decision making and hindered the ability to track equipment performance effectively.
Lastly, human factors, accounting for 5%, included inadequate training and manual data entry errors that further exacerbated the overall problem. Employees often lacked the necessary skills to utilize existing tools effectively, leading to mistakes that could have been avoided with proper training and support.

Implementing the DMS
In response to these challenges, Pertamina Drilling Services Indonesia embarked on the implementation of a comprehensive DMS designed to revolutionize the approach to maintenance data collection, management and access. The DMS leverages RFID technology, allowing tags to be attached to critical equipment. Technicians equipped with handheld devices can scan these tags, instantly inputting data into a centralized database. This not only eliminated manual data entry but also significantly reduced error rates, enhancing the overall accuracy of maintenance records.
The centralized database enables real-time access to critical information through web dashboards and mobile applications, enhancing operational transparency and decision-making capabilities. With this system in place, technicians can quickly retrieve maintenance histories, track equipment performance and access relevant documentation without sifting through piles of paperwork. This improved accessibility fosters a culture of accountability and encourages timely maintenance actions.
To ensure successful implementation of the DMS, the company adopted a structured, phased approach comprising three implementation stages.
In Phase 1, design and development focused on creating an intuitive UI/UX for web and mobile platforms, optimizing user experience and designing a robust system architecture, with an emphasis on user-centered design principles. In Phase 2, technology integration involved the procurement of RFID systems and necessary hardware components, followed by comprehensive setup and testing procedures and preparation of the supporting IT infrastructure. In Phases 3 to 5, deployment and integration encompassed a strategic pilot implementation across four drilling rigs, followed by full application development, integration with existing operational systems, and thorough user acceptance testing to verify that the solution met all requirements before wider deployment.
Through this methodical implementation strategy, the company successfully ensured stakeholder engagement throughout the process, effectively tested and refined the system in controlled environments, delivered comprehensive training to users, and established clear performance metrics to measure the success of this digital transformation initiative.
The DMS also offers advanced functionalities, including automated scheduling, digital documentation and parameter monitoring. Automated scheduling ensures that maintenance tasks are performed on time, reducing the likelihood of equipment failures due to neglect. Digital documentation eliminates the need for physical paperwork, streamlining the documentation process and ensuring that all records are stored in a single, easily accessible location.
By integrating digital twin technology, the company was able to gain a virtual representation of its assets, enabling live monitoring and predictive maintenance capabilities. This integration facilitates a holistic view of maintenance operations, allowing for anomaly detection and proactive forecasting of maintenance needs. The digital twin acts as a dynamic model of physical assets, enabling the company to simulate various scenarios and assess the potential impact of different maintenance strategies.

Transformational results
The implementation of the DMS has yielded remarkable improvements across Pertamina Drilling Services Indonesia’s operations. The planned maintenance compliance rate surged to 97%, demonstrating a marked improvement in adherence to scheduled maintenance. This increase in compliance not only enhances equipment reliability but also contributes to overall operational efficiency. Moreover, the company achieved a 75% reduction in documentation processing time, freeing up valuable resources for more strategic initiatives.
Perhaps the most significant achievement has been the elimination of major equipment failures since the DMS was implemented. This success underscores the effectiveness of the system in preventing breakdowns, leading to a 36% reduction in costs related to nonproductive time (NPT). The financial impact of these improvements is substantial, as reduced downtime translates directly into increased productivity and profitability.
Beyond operational improvements, the DMS has driven significant enhancements in HSE performance. Automated tracking has improved regulatory compliance, while proactive safety measures enable the identification of potential hazards before they escalate into incidents. By reducing human error and enhancing equipment reliability, the DMS has significantly mitigated risks across the company’s operations.
HSE performance improvement
The improvement in HSE performance is one of the most critical aspects of this digital transformation. With a more integrated system, Pertamina Drilling Services Indonesia can monitor compliance with safety and environmental standards more effectively. Proactive safety measures not only protect employees but also ensure that operations align with applicable legal and regulatory requirements. The implementation of the DMS has facilitated the establishment of a safety-first culture within the organization, where safety considerations are prioritized in every maintenance task.
The company has also adopted a more systematic approach to training employees in safety and the use of the new system. This training encompasses not only technical aspects but also builds awareness of the importance of safety in the workplace. Employees are now equipped with the knowledge and skills necessary to utilize the DMS effectively, reducing the likelihood of errors and enhancing overall safety performance.
Furthermore, the DMS allows for the documentation of safety incidents and near-misses, enabling the company to analyze trends and implement corrective actions. By fostering an environment where employees feel empowered to report safety concerns, the company is taking proactive steps to enhance workplace safety and minimize risks.
Future directions and conclusions
Digital transformation at Pertamina Drilling Services Indonesia is not an endpoint but rather the beginning of a longer journey. Future plans include further development of data-driven maintenance systems, focusing on analytics and artificial intelligence to enhance operational efficiency.
The journey of digital transformation so far illustrates the profound impact of technology on maintenance operations. By adopting an RFID-based DMS, the company has not only enhanced operational efficiency but also improved safety and compliance. The commitment to continuous innovation and adaptation serves as a foundation for setting new standards in maintenance management.
In summary, the integration of advanced technologies into maintenance practices represents a significant shift toward a more efficient and effective operational model. As Pertamina Drilling Services Indonesia continues to embrace a digital transformation, the lessons learned and successes achieved will serve as a blueprint for other organizations seeking to enhance their maintenance management strategies. DC
This article is based on a presentation at the 2025 IADC HSE & Sustainability Asia Pacific Conference, 14-15 May, Bangkok.