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Pareto of Production Losses Across a Site

Figure 2.9 A Pareto of production losses across a site. This Pareto indicates that most (89.4%) of production losses are associated with four process units. The next step would be to drill down into this data to determine the root causes of these outages and address them.

Pareto downtimes causes (machinery, exchangers, controls, etc.)

A Pareto made up of RCFA causes can assist your organization in determining:

1 The best types of training that might benefit your organization.

2 How to best use your predictive maintenance resources.

3 Where design upgrades could be justified.

Note that to generate this type of Pareto chart your organization will need to perform RCFAs to determine the root cause of failures. RCFAs are essential for organizations that wish to have operational reliability.

Figure 2.10 Pareto of causes of production losses over the last 12 months. This Pareto summarizes the reasons for unit outages. At a glance, management can see what is causing production losses. In this hypothetical example, we see that 68.7% of the process losses were caused by operational factors and heat exchanger issues. One conclusion you could draw from these results is that more operator training may be warranted to reduce process losses. Another recommendation that could stem from this Pareto is to review the present heat exchanger inspection program to see if improvements could be made.