Operations & Reliability

What we deliver

Most maintenance programs are built once and never re-tuned. Operating data accumulates in the CMMS, equipment fails for reasons no one tracks back, the same bad actors come back month after month, and the original FMECA quietly drifts out of date.

Our Operations & Reliability service is the loop that closes that drift. We work from your real work-order history, your failure records, and your downtime data to find what is actually costing you — then we run structured root cause analysis, prescribe specific corrective and preventive actions, and update your maintenance concepts so the same failure doesn't reach the same conclusion next time.

Core deliverables

Root Cause Analysis (RCA)

Structured investigation of failure events using 5-Whys, Fishbone (Ishikawa 6-M), and Fault Tree Analysis. IEC 62740-aligned reports with immediate, contributing, and systemic causes.

PM Optimisation (PMO)

Review of existing preventive tasks against actual failure data and OREDA benchmarks. Recommends interval changes, task additions, and tasks to drop — quantified by risk impact.

Bad Actor / Pareto Analysis

Pareto ranking of equipment by downtime, repair cost, and HSE consequence. Identifies the 20% of tags responsible for 80% of pain — and where RCA effort earns the highest return.

Defect Elimination Register

A live register that tracks every RCA finding through to closure — corrective action, owner, due date, verification of effectiveness. Stops findings from dying in spreadsheets.

Reliability Tracking (MTBF / MTTR)

Computation and benchmarking of MTBF, MTTR, and availability per equipment class from your CMMS event history. Establishes baselines and tracks the impact of every intervention.

FMECA & RCM Feedback Loop

Every confirmed root cause updates the originating FMECA. Every PMO recommendation revises the RCM decision. The maintenance concept register stays current — not frozen at handover.

How an engagement works

01

Failure history ingestion

We pull work-order, failure code, and downtime data from your CMMS — Maximo, SAP PM, eMaint, Fiix, Asset Care — and normalise it against ISO 14224 taxonomy.

02

Bad-actor identification

Pareto by downtime cost, repair cost, and HSE consequence. The output is a short list of equipment where root cause analysis will repay itself within a single avoided failure.

03

Root cause analysis on top events

Structured RCA on each priority event — method matched to severity. Immediate, contributing, and systemic causes documented per IEC 62740. Evidence linked, conclusions defensible.

04

Corrective & preventive action specification

Each root cause produces specific actions: design change, procedure change, PM revision, spare strategy change, training need. Owner, due date, and verification criteria attached.

05

Concept & RCM update, handover

Findings flow back into the source FMECA and RCM. The concept register is updated, the defect elimination register handed to your team, and an optional retainer keeps the loop running.