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A production outage is when a processing unit is shut down due to a machinery, equipment, or processing issue. Unplanned production losses are especially costly. A great deal of effort is expended to ensure production losses are minimized. Production losses outages are typically reported in, 1) hours or days of downtime, 2) pound of production lost, 3) barrels of production lost, and 4) dollars of production lost, etc. If a production unit has no “make-up” capacity, then the production lost during an outage is lost forever.

Figure 2.8 A trend of machinery outage cost will tell you the magnitude of the production losses over a period of time and if the losses are increasing, decreasing, or staying constant.

Here are a few types of plots that can be used to track process outages:

1 Production losses related to machinery outages (see Figure 2.8)

2 Breakdown of unit outages (see Figure 2.9)

3 Outage downtimes causes (machinery, exchangers, controls, etc.) (see Figure 2.10)

4 Root causes of outages (see Figure 2.11)