GUSTYAI Copilot

Reliability Report

Insights from marked events — weak links, prevention gaps, and cost performance

← Asset Events

Assets analysed

15assets
22 events marked
Marked events22
Total events37
Marked / event1.5 avg

P1 prevention opportunities

7WOs
could have prevented P1
No PM plan2
Interval too long5
Not on time0

Downtime — total recorded

45.0hrs
5 events flagged
HX-101 — WO-48179
18.0 h
MOT-402 — WO-48311
9.0 h
COMP-501 — WO-48349
8.0 h

Cost overrun — over-budget WOs

+11%
6 work orders
Worst overrun+23%
Avg overrun+11%
Assets affected6

Asset risk ranking — weak links

Which assets need attention?

Scored on P1 events, downtime hours, marked findings and open work. Hover a row to review or dismiss.

1
HX-101
Heat Exchanger
27
2
MOT-402
Motor
23
3
COMP-501
Compressor
22
4
P-101
Pump
18
5
G-101
Generator
9
6
HX-202
Heat Exchanger
6
7
P-102
Pump
5
8
V-203
Valve
3
Assets with open P15
Assets with open WOs7
Assets with downtime5

Prevention opportunities

Could these failures have been avoided?

Events where maintenance strategy gaps contributed to the failure

No PM plan2
WO-48310MOT-402CMBearing failure — smoke from housing
WO-48100G-101CMFailed start test — no-start condition
Interval too long5
WO-48291P-101CMMechanical seal failure — active leakage
WO-48350COMP-501CMHigh vibration alarm — interstage bearing
WO-48201MOT-401CMInsulation resistance low — winding degradation
WO-47200MOT-402PMBearing lubrication PM
WO-48180HX-101CMTube bundle leak — cross-contamination risk

Cost performance — budget overruns

Which work orders exceeded budget?

Ranked by percentage over planned cost

1
P-102WO-47899
+23%
2
HX-202WO-47150
+13%
3
HX-101WO-47300
+9%
4
MOT-401WO-48201
+9%
5
COMP-501WO-47350
+8%
6
MOT-402WO-47200
+5%
Total overspend€ 2.980
Largest single overrun€ 250

Downtime follow-up queue

Events to investigate for root cause

Sorted by downtime hours — largest impact first

1
HX-101WO-48179
18.0 h
2
MOT-402WO-48311
9.0 h
3
COMP-501WO-48349
8.0 h
4
P-101WO-48290
6.5 h
5
HX-202WO-48130
3.5 h
Total downtime45.0 h
Worst single event18.0 h
Assets affected5

Reliability issues

Dates not honored

Events where planned or due dates were missed — directly impacts reliability metrics

Due date not honored3
WO-48291P-101CMMechanical seal failure — active leakage
WO-48350COMP-501CMHigh vibration alarm — interstage bearing
WO-48180HX-101CMTube bundle leak — cross-contamination risk
Planned date not honored3
WO-48102P-102CMVibration increase — coupling misalignment
WO-48050V-203CMValve hunting — trim wear causing oscillation
WO-48100G-101CMFailed start test — no-start condition
Due dates missed3
Planned dates missed3

Data quality & inspection

Data integrity and over-inspection findings

Data errors reduce asset metric reliability — over-inspection wastes PM capacity

Possible over-inspection2
WO-47800COMP-503PMVibration route measurement — all OK
WO-47900FAN-101PMVibration route measurement — within limits

All readings normal — consider reducing inspection frequency

Booked on wrong tag2
WO-48220FILT-301CMHigh dP alarm — premature filter blockage
WO-47800T-201PMLevel gauge calibration & vent check

Key takeaways for management

Summary of findings requiring prioritisation

7 work orders were marked as P1 prevention opportunities — 2 failure modes had no PM plan, 5 had an interval that was too long. Review PM scope and inspection frequencies.

7 preventable failures identified — 2 failure modes not covered by any PM plan, 5 events where warning signs preceded the failure. Review PM scope and intervals.

45.0 h total downtime — HX-101 (18.0 h) and MOT-402 (9.0 h) are the largest contributors. Root cause investigation recommended.

Cost estimating accuracy is low — overruns average +11% across 6 work orders. Review scope definition and cost estimation process.

2 data quality issues found — wrong tag bookings distort per-asset reliability metrics and maintenance history. Correct before next reporting cycle.

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