Maintenance and reliability

A plant that maintains everything equally maintains the wrong things. Maintenance effort is finite, and spending it evenly across assets means the machine whose failure stops the line gets the same attention as the one with three spares in the cabinet.

Rank by consequence, not by age or cost

The question is not how likely a machine is to fail. It is what happens when it does.

Rank every asset on what its failure costs: production stopped, product scrapped, a safety event, a regulatory exposure, or nothing anyone notices before the next shift. That ranking, not the capital value, decides where preventive effort goes.

Two things this exposes immediately in most plants: