Preliminary Plant Reliability Assessment

Oil & Gas · Refining · Petrochemicals · Mining & Minerals

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Profile Anonymous facility profile — non-confidential
Section A Asset registry & criticality classification
Q1. Is your critical equipment inventory fully registered in your CMMS (Computerized Maintenance Management System) / ERP (Enterprise Resource Planning) system?
Q2. What percentage of total equipment is formally classified as critical?
Q3. What methodology is used for criticality ranking? Select all that apply
Section B Maintenance strategy & work management
Q4. What maintenance strategies are actively used at your facility? Select all that apply
Q5. Do you formally review and optimize PM (Preventive Maintenance) task lists after turnarounds or major inspections?
Q6. What is the approximate split of your annual maintenance spend? Enter percentages that total 100%. Typical world-class target: Scheduled ≥ 70%, Unscheduled ≤ 20%, Emergency < 10%.
Section C Condition monitoring & equipment health
Q7. Which condition monitoring / PdM (Predictive Maintenance) technologies are deployed? Select all that apply
Q8. Is your equipment health monitoring system integrated with the control system or historian?
Generic comments only — no site names, vendor names, or proprietary details.
Section D Failure analysis & knowledge capture
Q10. Have FMEA / FMECA (Failure Mode &amp; Effects Analysis) been completed for critical assets?
Q11. What asset information is captured and maintained in your CMMS / ERP? Select all that apply
Q12. Do you have a formal workflow to capture RCFA (Root Cause Failure Analysis) for bad actors?
Q13. How is operator field knowledge (observations, near-misses, anomalies) captured? Select all that apply
Section E Reliability modelling & performance metrics
Q14. Do you have a RAM (Reliability, Availability &amp; Maintainability) model for your facility or key units?
Q15. Which KPIs (Key Performance Indicators) are formally tracked for reliability performance? Select all that apply
Q16. How would you rate the accuracy and completeness of your equipment failure data for trend analysis?
Section F Digital systems & data infrastructure
Q17. Which primary digital systems are used for reliability and maintenance activities? Select all that apply
Q18. How well are your process historian data and maintenance records linked or correlated?
Q19. Are electronic devices (tablets, smartphones, wearables) used during operator / technician field rounds?
Q20. Are laboratory samples (lube oil, corrosion coupons, process fluid) tracked in a LIMS (Laboratory Information Management System) or equivalent?
Section G AI (Artificial Intelligence) & advanced analytics readiness
Q21. Does your facility have sufficient clean, timestamped historian data to support predictive analytics?
Q22. What is your organization's current stance on AI-assisted reliability tools?
Q23. Which AI / advanced analytics use cases are of highest interest? Select all that apply
Q24. How would you rate your team's capability to interpret and act on AI-generated reliability insights?
Section H Top reliability challenges & comments
Free text — no facility names, locations, or confidential details please.