Do you have questions? Contact us.

FAQ

6. Does the criticality analysis need to consider the probability of failure, or just the consequences of its occurrence?

It depends on the situation. From Operivo's experience, incorporating the probability of failure in the Criticality Analysis can lead to variability in its results. Nevertheless, we recommend using the probability of failure or its manifestation in the form of criticality in parallel with the results of the Criticality Analysis when making certain decisions.

5. What comes next after the critical analysis?

"The next step is often the optimization of Preventive Maintenance, implementing predictive elements, analyzing the risk of machine aging, or organizing data in CMMS/EAM. Criticality analysis along with technical condition assessment can also serve as a practical set for prioritizing investment initiatives."

4. Does the criticality analysis need to cover all assets?

This is recommended, but not always possible. At the preparatory stage, we determine which assets are subject to analysis and whether they can be covered by a single criticality ranking or if dedicated criteria need to be developed. A good example is organizations that possess network and volumetric assets.

3. How long does the criticality analysis take?

The duration depends on the amount of assets (number of devices, installations) and data availability. Typically, it ranges from a few weeks to several months, with the first and most important actions being workshops on aligning the criteria.

2. Is a criticality analysis necessary if we have a CMMS/EAM?

It depends. A CMMS/EAM without properly defined criticality may not offer certain functions, such as work prioritization and preventive planning. However, in most cases, the lack of criticality analysis will not impact the daily operation of CMMS/EAM systems.

1. Is criticality analysis just a classification of machines A/B/C?

No. The classification itself is just the beginning. What is crucial is how the criticality ranking affects the maintenance strategy, prevention, parts inventory, and investment decisions.

Customized services

Development of Technical Asset Criticality Analysis

We design and conduct criticality analysis of machines, installations, and technical systems based on the real consequences of failures, such as safety, impact on production, costs, quality, and regulatory compliance.

The analysis is tailored to the specifics of the organization, rather than based on a rigid model.

Utilization of machine criticality in Asset Management processes

We help translate the results of criticality analysis into specific operational decisions: differentiating maintenance strategies, scopes of prevention, frequencies of inspections, levels of spare parts inventory, and priorities for response to failures.

Among the most commonly encountered scenarios for utilizing equipment criticality is treating it as a starting point for building or optimizing Preventive and Predictive Maintenance.

As a result, maintenance activities focus where the risks and potential losses are greatest.

Criticality analysis review

We increasingly encounter situations where the Criticality Analysis has already been conducted, but it does not meet the needs of the organization. In such cases, we verify the current criticality ranking and asset structure to then make the necessary adjustments and implement the results into operations.

Why Operivo?

The scope of Criticality Analysis includes:

identification of the assets subject to analysis (machines, lines, systems),
defining criticality criteria (including safety, production, costs, quality, environment),
workshops with maintenance teams, production, and others,
preparation of data for CMMS / EAM,
maintenance and operational processes considering criticality.

Scope

We work workshop-style and analytically, in close collaboration with the Client's technical, operational, and health and safety teams. We utilize historical data, operational knowledge, and team experiences, avoiding "analysis for the sake of analysis." Each stage concludes with agreed conclusions and deliverables.

Method of work

The effects of implementing and consistently utilizing Criticality Analysis include:

a clear and agreed ranking of asset criticality,
better prioritization of maintenance work,
rational planning of prevention and prediction,
support for investment and modernization decisions,
a real reduction in the risk of downtime and critical events.

Results

The Operivo team has many years of experience in criticality analyses for industrial plants across various sectors. We work in both high-safety environments and organizations that are just beginning to organize their approach to managing technical assets. Among the sectors for which we have developed Criticality Analyses of assets are, among others, municipal water-sewage networks, heating networks, pharmaceuticals, energy, chemicals, and oil & gas.

Experience

Typical problems with Criticality Analysis

All machines are "critical"

In many organizations, every failure is treated as critical because there is no objective and agreed-upon ranking of criticality.

As a result, Maintenance operates reactively, and priorities are set ad-hoc, often under the pressure of production or individual incidents, rather than real business risk.

Criticality Analysis exists only in Excel

Often, the criticality analysis has been conducted only once – for example, for audit purposes or CMMS implementation – and is not used in daily decision-making.

The ranking does not influence preventive plans, parts inventory, investment decisions, or UR strategy, thereby losing its operational value.

Criticality Assessment of Technical Assets

The criticality of machines and installations is one of the fundamental pieces of information for Maintenance.

Criticality Analysis or Criticality Assessement allows for decision-making regarding maintenance, investments, replacements, and modernization of assets, and often serves as a basis for further actions such as implementing Preventive or Predictive Maintenance.

At Operivo, we assist organizations in developing a practical and tailored criticality ranking, conducting analysis, and integrating its results into operational processes.

Operivo Sp. z o.o.

Aleja Jana Pawła II 27

00-867 Warsaw

+48 533 373 200

europe@operivo.com