Reliability KPIs

[ww2i]

How do you identify bad actors among pumps, exchangers, or compressors before reliability KPIs deteriorate?
Please share some good leads.

[neo]

That's an intelligent one!
There has to be a different approach to identify a bad actor, which is often not the equipment that failed catastrophically...
It is the one:
consuming disproportionate maintenance hours
requiring repeated interventions
creating process instability
generating nuisance alarms
forcing operators into workarounds
repeatedly approaching trip limits... before actual failure occurs.
A pump opened 4 times in 8 months for seal issues is already a bad actor even if availability still looks acceptable.
This is where the things should take a start.

[ivani1]

I would say building pain index would support here instead of approaching towards that based upon MBTF only (picked up on normal basis).
See the attachment here, how it indicates an associated weight of every parameter:

Snip20260524_46.png

This catches assets that are:

• degrading silently

• not yet causing downtime

• but consuming organizational attention

Many plants miss this because KPIs focus only on downtime.

[neo]

Is this indicative or from an actual document rating all these cases?

I would say building pain index would support here instead of approaching towards that based upon MBTF only (picked up on normal basis).
See the attachment here, how it indicates an associated weight of every parameter:
Snip20260524_46.png
This catches assets that are:

• degrading silently

• not yet causing downtime

• but consuming organizational attention

Many plants miss this because KPIs focus only on downtime.