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Each service stands on its own, but they are built to feed one another: the hierarchy carries the criticality, the criticality scopes the FMECA, and the FMECA decides what the PMs and spares need to cover.
Asset registers and hierarchies
The register is the foundation. If it is wrong, every KPI, PM and spares decision built on it inherits the error.
We start from what you already have: P&IDs, existing CMMS extracts, O&M manuals and work-order history, loaded exactly as you supplied them. A desk study builds a first-pass hierarchy, and a site walkdown confirms it item by item, with photographs of every nameplate.
- Functional location and equipment hierarchy to ISO 14224 taxonomy levels
- Equipment classification and noun-modifier descriptions (for example PUMP, BOILER FEED)
- Nameplate data: make, model, serial, rating
- Tagging scheme where none exists, and physical tags fitted on site
- Desk-study records clearly marked as unverified until walked down
- Type
- 2FV 160M-4
- No.
- 324-118306
- kW
- 411
- V
- 400 Δ
- A
- 20.6
- r/min
- 1460
- Hz
- 50
- cos φ
- 0.84
- Frame
- 5160M
- IP
- 55
- Ins. cl.
- F
- Bearings
- 6DE 6309-2Z/C3NDE 6209-2Z/C3
- ManufacturerRecorded exactly as stamped, then matched to one standard spelling across the site.
- ModelLinks the motor to its manual and to identical motors elsewhere.
- Serial numberTies the record to this physical unit, so history follows it if it is swapped.
- RatingPower, voltage, current and speed go into the equipment attributes.
- Frame and protectionFrame size, IP rating and insulation class decide which spare motors are interchangeable.
- BearingsBecome spares lines on the motor's bill of materials, described as BEARING, BALL.
Criticality assessment
Criticality decides where analysis and maintenance effort goes.
We assess each equipment item against safety, environment, production and cost consequences using your company risk matrix, or a NORSOK Z-008 approach where you have none. Redundancy is accounted for: a standby pump is not rated the same as the duty pump it backs up.
- Consequence and likelihood scoring with the reasoning recorded per item
- Safety and environmentally critical elements identified and flagged
- Criticality bands loaded into your CMMS against each equipment record
FMECA and RCM
Enough analysis to drive decisions, anchored to evidence.
FMECA is carried out to IEC 60812, using your scoring rubric where one exists. Each failure mode is checked against your work-order history and matched to the PM that currently covers it, so gaps and duplicated effort are visible line by line.
Where time or data is short, we run RCM-lite on the critical systems first: the functions that matter, the failure modes that actually occur, and the least-cost task that prevents or detects each one. Full RCM to SAE JA1011 follows where the risk justifies it.
- FMECA worksheet with severity, occurrence and detection justified per row
- Bad-actor list from corrective work orders
- PM gap analysis: failure modes with no task, and tasks with no failure mode
Maintenance strategy and PM procedures
Replacing "check pump" with a task a technician can carry out and record.
Every PM is written against named failure modes. Steps state the action, the object, the method and a measurable acceptance criterion. Anything we cannot confirm from the nameplate, the manual or the site is marked for confirmation, never guessed.
- Task selection per failure mode: condition-based, time-based, redesign or run to failure
- Procedures with isolation and LOTO points, PPE, tools, parts and return to service
- Site photographs embedded so the technician finds the right item
- Statutory inspection on its own register and calendar, with evidence templates
CMMS data and migration
Getting good data into the system, and proving it arrived intact.
We prepare import files in the format your system expects, load them with your administrators, and reconcile the result back to the source row by row. The same approach works for a first CMMS, a move between systems, or a clean-up of a live one.
Not sure how much clean-up a live system needs? Start with a free register health check.
| System | Typical work |
|---|---|
| SAP PM | Functional locations, equipment, superior equipment and position, LSMW load files, task lists |
| IBM Maximo | Locations, assets, classifications, job plans and PMs |
| MaintMaster | Hierarchy and asset import, PM routines |
| AMOS | Vessel component structures and planned maintenance jobs |
| Brightly | Asset Essentials base configuration, asset and parts imports |
Spare part reviews and stores surveys
Knowing what is on the shelf, what it fits, and what is no longer needed.
We carry out full spare part reviews and stores surveys. Our engineers survey the stores location by location, photograph and record each part, and describe it in noun-modifier form so duplicates show up on sight.
Each spare is then matched to the equipment it serves in the finished asset hierarchy. That builds your bills of materials, and it shows which spares no longer fit anything on site.
- Stores survey: every location and bin recorded, with photographs and quantities on hand
- Full review of the materials master against what is physically in stores
- Spares matched to their equipment in the finished hierarchy, forming the BOMs
- Obsolete spares flagged: parts for equipment no longer on site, or superseded by the manufacturer
- Duplicates identified across descriptions, part numbers and store locations
- Critical spares set from the FMECA consequence and supplier lead time, with a stocking policy
What you receive
Everything is yours, in open formats, with no licence attached.
| Deliverable | Format |
|---|---|
| Asset hierarchy and register | CMMS import files plus a reviewable Excel workbook |
| Tagging and naming standard | Short written standard with the class list |
| Criticality register | Workbook with scoring reasons per item |
| FMECA and gap analysis | Worksheet and a written report |
| PM procedures | Word documents in your template or ours |
| Statutory register | Workbook with evidence templates |
| Stores survey and spares review | Workbook of every part with location, photographs, equipment match and obsolete flags |
| BOMs and critical spares | Import files and stocking policy |
| Reconciliation report | Source-to-CMMS audit, row by row |
Common questions
Will this disrupt operations?
Very little. Desk work, analysis and procedure writing happen off site. Walkdowns are planned with your operations team, and data loads go in during agreed windows.
Do we keep our existing data?
Yes. We work from your data as delivered and reconcile every change back to it. Existing equipment numbers that carry history are protected, and nothing is deleted without your sign-off.
Are we tied to you or to a software vendor?
No. The outputs follow published standards and arrive in open formats, so your own team or another contractor can maintain them.
Where do you usually start?
With one area or one production line: a register, criticality and FMECA for that scope, so you can judge the work before it is extended to the rest of the site.
Do you work outside the UK?
Yes. We work across the UK, Europe and the US.
Start with one area
Most clients begin with a single line or system: register, criticality and FMECA for that scope. It shows you how we work before you commit to the rest of the site.