Your hidden gold
Data analysis can be done anywhere with a computer and connections to receive and transmit. While your operations are shut down or slowed down due to the current global health crisis, we can examine your data and carry out analysis, identify problems for resolution, help you increase reliability for when you get back up to full capacity, and identify data problems for future resolution.
You are normally too busy to do this, even though the payback can be high. You may not have someone to do the analysis, or it may take too much time producing reports you can use, or analyzing the data on spreadsheets.
Many companies talk about continuous improvement, performing root cause analysis and making small improvements. Do you know where it is best to apply it? Do you know why?
Large volumes of data are being gathered on maintenance work orders, yet not being used effectively to identify and resolve costly problems. It may be difficult to access, incomplete, inaccurate, or unfit for purpose in other ways. Or, you may not have anyone to extract and analyze it. Many companies simply do not have the reliability engineering personnel. We do, and we can help.
What can you do with that data?
Here are some of the problems you might be struggling with:
- Chronic (repetitive) reliability problems on any but the most obviously critical pieces of equipment go undetected. Repeat failures, many due to the same causes are not eliminated.
- Major problems are easy to spot and get all the attention without use of your data, but many smaller problems get missed. They add up to a lot of downtime and cost.
- Record keeping in the maintenance software isn’t complete, nor easy to access, so proving that required checks and inspections were carried out is difficult if not impossible.
- Failure to report could result in product being discarded in regulated industries such as food and pharmaceutical.
- Common problems that contributed to excessive downtime are not addressed.
- Many equipment and operational problems have common root causes that are not directly related to the equipment itself. Lack of training, incorrect materials or parts, insufficient parts on hand, and omission of key steps in repairs in order to cut corners are examples of such problems.
We can help
We have experienced reliability engineers who are familiar with maintenance work order data and its data quality problems. We’ve learned through experience how to deal with those problems and the answer in the short term isn’t simply to “get better data”. That takes too long. We have learned to work with what we are given and still get results.
If you have good data, then it can be used in problem identification and solving. We have access to our own database of equipment and system common failures, failure codes, and identifiers (based on ISO 14224) which can be used to help in “filling in the blanks” when it comes to unknowns arising from some of those work order records.
We can analyze your Work Order data and use our database to help in identifying the sort of problems you might have. Some will be easy to spot if the data is of good quality.
If the data is of poor quality, then we can still spot many common problems. After all, what happens in your pumps, compressors, etc. is not all that different from what happens to those of others in our database. No matter how unique your environment may be, the equipment you use doesn’t know the difference. The same or similar equipment in other industries behaves in just the same ways. We can get a good idea of your situation even if your data is incomplete.