Proactive Asset Integrity Management in High-Risk Critical Facilities: A Comprehensive Review and Strategic Framework

Asset Integrity Management (AIM) is vital for ensuring the safety, reliability, and sustainability of high-risk industrial assets in sectors such as advanced manufacturing, oil and gas, energy, and petrochemicals. As industrial systems grow increasingly complex, interconnected, and digitally enabled, traditional maintenance approaches often struggle to manage dynamic risks, performance variability, and long-term asset health. This study presents a comprehensive review of AIM methodologies and proposes a proactive, integrated framework that unifies Risk-Based Inspection (RBI), Reliability-Centered Maintenance (RCM), and Total Productive Maintenance (TPM) within a single strategic model. The framework aligns strategic objectives, operational processes, and key performance indicators (KPIs), emphasizing risk mitigation, operational efficiency, workforce capability, and sustainability, while addressing implementation challenges such as leadership engagement, skill gaps, data governance, and digital integration. Conceptually validated across high-reliability industrial contexts, the model enhances Reliability, Availability, Maintainability, and Safety (RAMS) and, by integrating Artificial Intelligence (AI), the Internet of Things (IoT), and Digital Twins, advances Maintenance 4.0—enabling predictive, intelligent, and sustain-able maintenance ecosystems that minimize unplanned downtime, reduce lifecycle costs, and strengthen organizational resilience and long-term value creation.