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Equipment criticality: What is the current situation of your plant equipment criticality?

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  • Community Leader

Hi all,

Having a well-established equipment criticality process is a key factor to help us prioritizing our daily maintenance tasks, as well as budgeting money for future investments. The reality is, if we want to improve our plant performance and business results, we need to know how critical our equipment are.

Some companies use production and maintenance to define how critical their assets are, while other use a multidisciplinary process, combining maintenance, production, safety, health and environment, as well as probability.

However, it is still not a hard task finding companies that do not have any criticality analysis done for their equipment.

This week’s question is:


What is the current situation of your plant equipment criticality? 


Tell us if you have an equipment criticality process established in you company, how you define your asset criticality, what do you consider when analyzing it, how often you review it and how important it is for your daily tasks.



Raul Martins

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We have ”Asset Criticality Assessment”  to determine the criticality based on several elements ( consequence of failure X Equipment importance in different production areasX Equipment reliabilityX Utilization rate of the available capacity) it is done among cross-functional team from multiple areas  

Edited by Mohammed tawili
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  • Community Leader

Hi @Mohammed tawili,

That seems to be a really complete assessment to check how critical an equipment is for the business. 

Would you mind if I ask you a few more questions to understand a bit more about how this method works?

1- All different areas are considered as important as the others or some might be considered more important? E.g.: an equipment that may cause a big damage to the environment might be considered critical, although it might not cause any bad consequences in terms of production?

2- How long it takes to assess (on average) one single asset?

3- How often do you review your equipment criticality?



Raul Martins

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  • Community Leader

Hi @Sumanan,

It really varies from company to company.

Generally speaking, some businesses assess their equipment criticality by combining different factors.

For instance:

     For an equipment XYZ

Event probability: how likely is it to fail within the next 12 months? High likely.

Production consequence: There would be no production losses - Low consequence.

Maintenance consequence: This would cost $2,000 - Low consequnce.

Environment consequence: There would be no environment damage - Low consequence.

Health and Safety: One person or more could die - High consequence.


For the example above, although the company would not lose any production or would not face any considerable maintenance costs, the event of failure could result in one person or more dead, which, combined with the event probability, could be considered a critical equipment.


This is a very simple example, and many other factors should be considered in order to determine the asset criticality. But could you get an idea about how this works?

If you have any more questions, feel free to ask us.



Raul Martins


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Hi Raul

for example, elevators are more reliable and easier to maintain than in the past

For older models, there are 2 ways
most critical components are switch breakers (380V 32A/16 A) 
because older elevators have induction engines without current inventors
with WYE/DELTA start wiring systems and reliability is the function of number run (count) call elevators  (frequency per 24 hours

for 7 stations 35 flats 120 persons is from 240 (min 120x2) to 4800 start/stop average 563,1 +/- from houses to houses(assets/assets))

2) total replacement  of induction motor wiring - the function of load elevators 
(more loads up to limit load (up to 300kg - 4 big and heavy persons,  or 450kg 8 very big and heavy persons etc .....)

and that is very probably functions, so our open ERP system  ADempiere
give us pieces of information from databases about warehouses, purchase orders, 
material receipt, MRP and maintenance orders/ manufacturing orders/sales order CRP and level of switch breakers 
380V (16/32/64 Amps) in storage (warehouses) is calculated from Williams formula

but for induction engines is 5 days (replace engine 8-16 hours-2 days, replace wired 1, heat 3 days and 
fix induction engines 8-16 hours 2 days) - this workflows is for all powers (3,4,5,6,7,8,10,12,18 kW)  replacement

from old to new is not possible (slip ring induction engines have big prices ).

Its not so simple to build MRP/DRP/CRP and postgreSQL/oracle_XE database give very interesting results from SQL queries.



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