Avoidable operator errors

  •  Missing or inadequate availability concepts and contracts with appropriate bonus/penalty regulations
  • Manufacturer dependencies, e.g. lack of access to data for condition-based monitoring as a basis for predictive maintenance and lifetime prediction of important components and equipment
  • Insufficient quality levels for electrical installation, EMC, IT/OT
  • Lack of redundancy for important components
  • Manufacturer service (full service, partial service, 24/7 hotline) that is not negotiated together with the delivery of the system can be very expensive
  • Insufficient spare parts packages and lack of long-term delivery commitments for important components
  • Unnecessary system diversity (e.g. SCADA, HMI, fieldbus systems, lubrication systems)
  •  Limited connectivity to systems such as SCADA/BMS and CMMS/CAFM system  	
  •  Inadequate emergency stop concepts with disadvantages for plant availability
  •  Insufficient documentation requirements

Phase 1: Before procurement

  • Late and insufficient integration of future maintenance into the assembly process, so that valuable know-how from assembly, final adjustment work and commissioning for operation is missing

Phase 2: Installation

  • Missing or insufficient description of the entire commissioning process that meets the legal and normative requirements, e.g. a complete risk assessment that fulfils all requirements of the Ordinance on Industrial Safety and Health (DE: Betriebssicherheits-verordnung), including the individual specifications for recurring inspections, such as inspection period, inspection content and the requirements for the future inspector (competent person)
  • Undocumented employee instructions based on operating instructions to be drawn up as a result of the risk assessment
  • Insufficient safety and technical inspections to clarify the possibility of acceptance (acceptance without defects, acceptance with defects, refusal of acceptance due to significant defects in accordance with § 12 Para. 3 VOB/B or § 640 BGB) and the permissibility of providing work equipment
  • Fictitious acceptance, e.g. by careless commissioning (VOB); Attention: Differences between VOB and BGB contracts

Phase 3: Commissioning

Phase 4: Operation

  •  Unclear targets, e.g. availability requirements or budgets
  • Missing key figures
  • Missing or incomplete processes, e.g. of maintenance, recurring inspection or handling of service requests (ticket system?)
  • Improper staff selection, as necessary qualifications (verifiable qualifications!) are not known or have not been checked —> Selection culpability
  • Inadequate (verifiable) staff instructions —> Instruction culpability
  • Lack of or inadequate (verifiable) employee controls  —> Control culpability
  • Missing/insufficient documentation of inspections of installations requiring monitoring and inspection
  • Missing/insufficient condition monitoring to be able to act in time before and in case of failures of important components
  • Lack of problem management: Lack of systematic investigation of faults that have already occurred or possible faults in order to avoid faults in the future or to remedy them quickly, e.g. by means of a workaround
  •  Lack of concepts to predict EOL (End of Life) for major components
  • Lack of monitoring of components to predict EOL
  • Lack of regular review of necessary measures due to due updates or announced discontinuations
  • Late planning of RRM measures to ensure sufficient lead time for the procurement of components (supply chain problems!) and their replacement (availability of service providers)

Phase 5: Retrofit/Revision