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Criticality Analysis

Prioritizing Your Assets for Maximum Impact

The Resource Problem

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Limited Time

Your team can't maintain everything at the highest level. Hours in a day are finite.

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Limited Budget

Not every asset deserves premium spare parts and monitoring equipment.

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The Solution

Criticality analysis ranks assets by importance, so you invest resources where they matter most.

Same Equipment, Different Consequences

⚠️ Pump A - Critical

Feeds the main reactor

If it fails, the entire plant stops

€100,000/hour

in lost production

✓ Pump B - Non-Critical

Backup for utility system

If it fails, switch to alternate

Fix it next week

No production impact

The Three Dimensions of Criticality

1

Safety & Environment

What happens to people and the planet if this asset fails?

Often overrides the others

2

Production Impact

Does the whole plant stop, or just one line? Is there redundancy?

Lost revenue per hour

3

Repair Cost

How expensive and complex is the repair? Special parts needed?

Time & money to restore

The 1-5 Scoring System

Safety Impact Example

5
Potential fatality or major environmental disaster
4
Serious injury or significant environmental release
3
Medical treatment required or minor environmental impact
2
First aid only or contained spill
1
No safety or environmental impact

Running the Assessment

1

Define Scope

Start with one area or top 100 assets. Don't try everything at once.

2

Gather the Team

Operations, maintenance, safety, business knowledge. 4-6 people ideal.

3

Score Together

The discussion is as valuable as the score. Different views reveal hidden risk.

4

Validate Outliers

Question surprising scores. Does everyone agree?

5

Document

Publish rankings. Update CMMS. Make it visible and usable.

6

Review Annually

Criticality changes. Review after failures and process changes.

Different Rankings → Different Strategies

A-CLASS

High Criticality

  • Predictive maintenance
  • Vibration monitoring
  • Full spare parts stocked
  • Detailed failure analysis
  • Priority response
B-CLASS

Medium Criticality

  • Preventive schedules
  • Critical spares available
  • Standard procedures
  • Scheduled response
  • Regular inspections
C-CLASS

Low Criticality

  • Run to failure OK
  • Minimal spares
  • Repair or replace
  • Batch with other work
  • Basic monitoring

Get Started Today

Download the free Criticality Assessment Template

Includes scoring criteria, facilitation guide & sample assessment

reliox.org

Take our Maintenance Maturity Assessment to see where criticality fits in your improvement journey

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